Vaporization device systems and methods

ABSTRACT

Vaporizer devices and apparatuses are provided. In some implementations, a vaporizer device comprises a cartridge and a device body. The cartridge comprises a cartridge body having a first side and a second side opposite the first side, a first pair of heater contacts comprising a first plate coupled to the first side and a second plate coupled to the second side, and a heater comprising a wick, a resistive heating element in contact with the wick, the first plate, and the second plate. The wick and resistive heating element are suspended between the first plate and the second plate. The device body comprises a cartridge receptacle for receiving the cartridge and a second pair of heater contacts positioned to couple with the first pair of heater contacts when the cartridge is inserted into the device body.

CROSS-REFERENCE

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/920,225, filed Dec. 23, 2013, U.S. Provisional PatentApplication Ser. No. 61/936,593, filed Feb. 6, 2014, and U.S.Provisional Patent Application Ser. No. 61/937,755, filed Feb. 10, 2014which are entirely incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention is directed to improvements in electronicinhalable aerosol devices, or electronic vaping devices, particularly toelectronic aerosol devices which utilize a vaporizable material that isvaporized to create an aerosol vapor capable of delivering an activeingredient to a user.

SUMMARY OF THE INVENTION

In some aspects of the invention, the device comprises an inhalableaerosol comprising: an oven comprising an oven chamber and a heater forheating a vapor forming medium in the oven chamber to generate a vapor;a condenser comprising a condensation chamber in which at least afraction of the vapor condenses to form the inhalable aerosol; an airinlet that originates a first airflow path that includes the ovenchamber; and an aeration vent that originates a second airflow path thatallows air from the aeration vent to join the first airflow path priorto or within the condensation chamber and downstream from the ovenchamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol formed in the condensationchamber to a user.

In some aspects of the invention the oven is within a body of thedevice. The device may further comprise a mouthpiece, wherein themouthpiece comprises at least one of the air inlet, the aeration vent,and the condenser. The mouthpiece may be separable from the oven. Themouthpiece may be integral to a body of the device, wherein the bodycomprises the oven. The device may further comprise a body thatcomprises the oven, the condenser, the air inlet, and the aeration vent.The mouthpiece may be separable from the body.

In some aspects of the invention, the oven chamber may comprise an ovenchamber inlet and an oven chamber outlet, and the oven further comprisesa first valve at the oven chamber inlet, and a second valve at the ovenchamber outlet. The aeration vent may comprise a third valve. The firstvalve, or said second valve may be chosen from the group of a checkvalve, a clack valve, a non-return valve, and a one-way valve. The thirdvalve may be chosen from the group of a check valve, a clack valve, anon-return valve, and a one-way valve. The first or second valve may bemechanically actuated. The first or second valve may be electronicallyactuated. The first valve or second valve may be manually actuated. Thethird valve may be mechanically actuated. The third valve may bemechanically actuated. The third valve may be electronically actuated.The third valve may be manually actuated.

In another aspect of the invention, the device may further comprise abody that comprises at least one of: a power source, a printed circuitboard, a switch, and a temperature regulator. The device may furthercomprise a temperature regulator in communication with a temperaturesensor. The temperature sensor may be the heater. The power source maybe rechargeable. The power source may be removable. The oven may furthercomprise an access lid. The vapor forming medium may comprise tobacco.The vapor forming medium may comprise a botanical. The vapor formingmedium may be heated in the oven chamber wherein the vapor formingmedium may comprise a humectant to produce the vapor, wherein the vaporcomprises a gas phase humectant. The vapor may be mixed in thecondensation chamber with air from the aeration vent to produce theinhalable aerosol comprising particle diameters of average size of about1 micron. The vapor forming medium may be heated in the oven chamber,wherein the vapor is mixed in the condensation chamber with air from theaeration vent to produce the inhalable aerosol comprising particlediameters of average size of less than or equal to 0.9 micron. The vaporforming medium may be heated in the oven chamber, wherein the vapor ismixed in the condensation chamber with air from the aeration vent toproduce the inhalable aerosol comprising particle diameters of averagesize of less than or equal to 0.8 micron. The vapor forming medium maybe heated in the oven chamber, wherein the vapor is mixed in thecondensation chamber with air from the aeration vent to produce theinhalable aerosol comprising particle diameters of average size of lessthan or equal to 0.7 micron. The vapor forming medium may be heated inthe oven chamber, wherein the vapor is mixed in the condensation chamberwith air from the aeration vent to produce the inhalable aerosolcomprising particle diameters of average size of less than or equal to0.6 micron. The vapor forming medium may be heated in the oven chamber,wherein the vapor is mixed in the condensation chamber with air from theaeration vent to produce the inhalable aerosol comprising particlediameters of average size of less than or equal to 0.5 micron.

In some aspects of the invention, the humectant may comprise glycerol asa vapor-forming medium. The humectant may comprise vegetable glycerol.The humectant may comprise propylene glycol. The humectant may comprisea ratio of vegetable glycerol to propylene glycol. The ratio may beabout 100:0 vegetable glycerol to propylene glycol. The ratio may beabout 90:10 vegetable glycerol to propylene glycol. The ratio may beabout 80:20 vegetable glycerol to propylene glycol. The ratio may beabout 70:30 vegetable glycerol to propylene glycol. The ratio may beabout 60:40 vegetable glycerol to propylene glycol. The ratio may beabout 50:50 vegetable glycerol to propylene glycol. The humectant maycomprise a flavorant. The vapor forming medium may be heated to itspyrolytic temperature. The vapor forming medium may heated to 200° C. atmost. The vapor forming medium may be heated to 160° C. at most. Theinhalable aerosol may be cooled to a temperature of about 50°-70° C. atmost, before exiting the aerosol outlet of the mouthpiece.

In an aspect of the invention, the method comprises A method forgenerating an inhalable aerosol, the method comprising: providing aninhalable aerosol generating device wherein the device comprises: anoven comprising an oven chamber and a heater for heating a vapor formingmedium in the oven chamber and for forming a vapor therein; a condensercomprising a condensation chamber in which the vapor forms the inhalableaerosol; an air inlet that originates a first airflow path that includesthe oven chamber; and an aeration vent that originates a second airflowpath that allows air from the aeration vent to join the first airflowpath prior to or within the condensation chamber and downstream from theoven chamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol formed in the condensationchamber to a user.

In some aspects of the invention the oven is within a body of thedevice. The device may further comprise a mouthpiece, wherein themouthpiece comprises at least one of the air inlet, the aeration vent,and the condenser. The mouthpiece may be separable from the oven. Themouthpiece may be integral to a body of the device, wherein the bodycomprises the oven. The method may further comprise a body thatcomprises the oven, the condenser, the air inlet, and the aeration vent.The mouthpiece may be separable from the body.

In some aspects of the invention, the oven chamber may comprise an ovenchamber inlet and an oven chamber outlet, and the oven further comprisesa first valve at the oven chamber inlet, and a second valve at the ovenchamber outlet.

The vapor forming medium may comprise tobacco. The vapor forming mediummay comprise a botanical. The vapor forming medium may be heated in theoven chamber wherein the vapor forming medium may comprise a humectantto produce the vapor, wherein the vapor comprises a gas phase humectant.The vapor may comprise particle diameters of average mass of about 1micron. The vapor may comprise particle diameters of average mass ofabout 0.9 micron. The vapor may comprise particle diameters of averagemass of about 0.8 micron. The vapor may comprise particle diameters ofaverage mass of about 0.7 micron. The vapor may comprise particlediameters of average mass of about 0.6 micron. The vapor may compriseparticle diameters of average mass of about 0.5 micron.

In some aspects of the invention, the humectant may comprise glycerol asa vapor-forming medium. The humectant may comprise vegetable glycerol.The humectant may comprise propylene glycol. The humectant may comprisea ratio of vegetable glycerol to propylene glycol. The ratio may beabout 100:0 vegetable glycerol to propylene glycol. The ratio may beabout 90:10 vegetable glycerol to propylene glycol. The ratio may beabout 80:20 vegetable glycerol to propylene glycol. The ratio may beabout 70:30 vegetable glycerol to propylene glycol. The ratio may beabout 60:40 vegetable glycerol to propylene glycol. The ratio may beabout 50:50 vegetable glycerol to propylene glycol. The humectant maycomprise a flavorant. The vapor forming medium may be heated to itspyrolytic temperature. The vapor forming medium may heated to 200° C. atmost. The vapor forming medium may be heated to 160° C. at most. Theinhalable aerosol may be cooled to a temperature of about 50°-70° C. atmost, before exiting the aerosol outlet of the mouthpiece.

In an aspect of the invention, the device may be user serviceable. Thedevice may not be user serviceable.

In an aspect of the invention, a method for generating an inhalableaerosol, the method comprising: providing a vaporization device, whereinsaid device produces a vapor comprising particle diameters of averagemass of about 1 micron or less, wherein said vapor is formed by heatinga vapor forming medium in an oven chamber to a first temperature belowthe pyrolytic temperature of said vapor forming medium, and cooling saidvapor in a condensation chamber to a second temperature below the firsttemperature, before exiting an aerosol outlet of said device.

In an aspect of the invention, a method of manufacturing a device forgenerating an inhalable aerosol comprising: providing said devicecomprising a mouthpiece comprising an aerosol outlet at a first end ofthe device; an oven comprising an oven chamber and a heater for heatinga vapor forming medium in the oven chamber and for forming a vaportherein, a condenser comprising a condensation chamber in which thevapor forms the inhalable aerosol, an air inlet that originates a firstairflow path that includes the oven chamber and then the condensationchamber, an aeration vent that originates a second airflow path thatjoins the first airflow path prior to or within the condensation chamberafter the vapor is formed in the oven chamber, wherein the joined firstairflow path and second airflow path are configured to deliver theinhalable aerosol formed in the condensation chamber through the aerosoloutlet of the mouthpiece to a user.

The method may further comprise providing the device comprising a powersource or battery, a printed circuit board, a temperature regulator oroperational switches.

In an aspect of the invention a device for generating an inhalableaerosol may comprise a mouthpiece comprising an aerosol outlet at afirst end of the device and an air inlet that originates a first airflowpath; an oven comprising an oven chamber that is in the first airflowpath and includes the oven chamber and a heater for heating a vaporforming medium in the oven chamber and for forming a vapor therein; acondenser comprising a condensation chamber in which the vapor forms theinhalable aerosol; and an aeration vent that originates a second airflowpath that allows air from the aeration vent to join the first airflowpath prior to or within the condensation chamber and downstream from theoven chamber thereby forming a joined path, wherein the joined path isconfigured to deliver the inhalable aerosol formed in the condensationchamber through the aerosol outlet of the mouthpiece to a user.

In another aspect of the invention a device for generating an inhalableaerosol may comprise: a mouthpiece comprising an aerosol outlet at afirst end of the device, an air inlet that originates a first airflowpath, and an aeration vent that originates a second airflow path thatallows air from the aeration vent to join the first airflow path; anoven comprising an oven chamber that is in the first airflow path andincludes the oven chamber and a heater for heating a vapor formingmedium in the oven chamber and for forming a vapor therein; and acondenser comprising a condensation chamber in which the vapor forms theinhalable aerosol and wherein air from the aeration vent joins the firstairflow path prior to or within the condensation chamber and downstreamfrom the oven chamber thereby forming a joined path, wherein the joinedpath is configured to deliver the inhalable aerosol through the aerosoloutlet of the mouthpiece to a user.

In another aspect of the invention, a device for generating an inhalableaerosol may comprise: a device body comprising a cartridge receptacle; acartridge comprising: a fluid storage compartment, and a channelintegral to an exterior surface of the cartridge, and an air inletpassage formed by the channel and an internal surface of the cartridgereceptacle when the cartridge is inserted into the cartridge receptacle;wherein the channel forms a first side of the air inlet passage, and aninternal surface of the cartridge receptacle forms a second side of theair inlet passage.

In another aspect of the invention, a device for generating an inhalableaerosol may comprise: a device body comprising a cartridge receptacle; acartridge comprising: a fluid storage compartment, and a channelintegral to an exterior surface of the cartridge, and an air inletpassage formed by the channel and an internal surface of the cartridgereceptacle when the cartridge is inserted into the cartridge receptacle;wherein the channel forms a first side of the air inlet passage, and aninternal surface of the cartridge receptacle forms a second side of theair inlet passage.

In some aspects of the invention the channel may comprise at least oneof a groove, a trough, a depression, a dent, a furrow, a trench, acrease, and a gutter. The integral channel may comprise walls that areeither recessed into the surface or protrude from the surface where itis formed. The internal side walls of the channel may form additionalsides of the air inlet passage. The cartridge may further comprise asecond air passage in fluid communication with the air inlet passage tothe fluid storage compartment, wherein the second air passage is formedthrough the material of the cartridge. The cartridge may furthercomprise a heater. The heater may be attached to a first end of thecartridge.

In an aspect of the invention the heater may comprise a heater chamber,a first pair of heater contacts, a fluid wick, and a resistive heatingelement in contact with the wick, wherein the first pair of heatercontacts comprise thin plates affixed about the sides of the heaterchamber, and wherein the fluid wick and resistive heating element aresuspended therebetween. The first pair of heater contacts may furthercomprise a formed shape that comprises a tab having a flexible springvalue that extends out of the heater to couple to complete a circuitwith the device body. The first pair of heater contacts may be a heatsink that absorbs and dissipates excessive heat produced by theresistive heating element. The first pair of heater contacts may contacta heat shield that protects the heater chamber from excessive heatproduced by the resistive heating element. The first pair of heatercontacts may be press-fit to an attachment feature on the exterior wallof the first end of the cartridge. The heater may enclose a first end ofthe cartridge and a first end of the fluid storage compartment. Theheater may comprise a first condensation chamber. The heater maycomprise more than one first condensation chamber. The firstcondensation chamber may be formed along an exterior wall of thecartridge. The cartridge may further comprise a mouthpiece. Themouthpiece may be attached to a second end of the cartridge. Themouthpiece may comprise a second condensation chamber. The mouthpiecemay comprise more than one second condensation chamber. The secondcondensation chamber may be formed along an exterior wall of thecartridge.

In an aspect of the invention the cartridge may comprise a firstcondensation chamber and a second condensation chamber. The firstcondensation chamber and the second condensation chamber may be in fluidcommunication. The mouthpiece may comprise an aerosol outlet in fluidcommunication with the second condensation chamber. The mouthpiece maycomprise more than one aerosol outlet in fluid communication with morethan one the second condensation chamber. The mouthpiece may enclose asecond end of the cartridge and a second end of the fluid storagecompartment.

In an aspect of the invention, the device may comprise an airflow pathcomprising an air inlet passage, a second air passage, a heater chamber,a first condensation chamber, a second condensation chamber, and anaerosol outlet. The airflow path may comprise more than one air inletpassage, a heater chamber, more than one first condensation chamber,more than one second condensation chamber, more than one secondcondensation chamber, and more than one aerosol outlet. The heater maybe in fluid communication with the fluid storage compartment. The fluidstorage compartment may be capable of retaining condensed aerosol fluid.The condensed aerosol fluid may comprise a nicotine formulation. Thecondensed aerosol fluid may comprise a humectant. The humectant maycomprise propylene glycol. The humectant may comprise vegetableglycerin.

In an aspect of the invention the cartridge may be detachable. In anaspect of the invention the cartridge may be receptacle and thedetachable cartridge form a separable coupling. The separable couplingmay comprise a friction assembly, a snap-fit assembly or a magneticassembly. The cartridge may comprise a fluid storage compartment, aheater affixed to a first end with a snap-fit coupling, and a mouthpieceaffixed to a second end with a snap-fit coupling.

In an aspect of the invention, a device for generating an inhalableaerosol may comprise: a device body comprising a cartridge receptaclefor receiving a cartridge; wherein an interior surface of the cartridgereceptacle forms a first side of an air inlet passage when a cartridgecomprising a channel integral to an exterior surface is inserted intothe cartridge receptacle, and wherein the channel forms a second side ofthe air inlet passage.

In an aspect of the invention, a device for generating an inhalableaerosol may comprise: a device body comprising a cartridge receptaclefor receiving a cartridge; wherein the cartridge receptacle comprises achannel integral to an interior surface and forms a first side of an airinlet passage when a cartridge is inserted into the cartridgereceptacle, and wherein an exterior surface of the cartridge forms asecond side of the air inlet passage.

In an aspect of the invention, A cartridge for a device for generatingan inhalable aerosol comprising: a fluid storage compartment; a channelintegral to an exterior surface, wherein the channel forms a first sideof an air inlet passage; and wherein an internal surface of a cartridgereceptacle in the device forms a second side of the air inlet passagewhen the cartridge is inserted into the cartridge receptacle.

In an aspect of the invention, a cartridge for a device for generatingan inhalable aerosol may comprise: a fluid storage compartment, whereinan exterior surface of the cartridge forms a first side of an air inletchannel when inserted into a device body comprising a cartridgereceptacle, and wherein the cartridge receptacle further comprises achannel integral to an interior surface, and wherein the channel forms asecond side of the air inlet passage.

The cartridge may further comprise a second air passage in fluidcommunication with the channel, wherein the second air passage is formedthrough the material of the cartridge from an exterior surface of thecartridge to the fluid storage compartment.

The cartridge may comprise at least one of: a groove, a trough, adepression, a dent, a furrow, a trench, a crease, and a gutter. Theintegral channel may comprise walls that are either recessed into thesurface or protrude from the surface where it is formed. The internalside walls of the channel may form additional sides of the air inletpassage.

In another aspect of the invention, a device for generating an inhalableaerosol may comprise: a cartridge comprising; a fluid storagecompartment; a heater affixed to a first end comprising; a first heatercontact, a resistive heating element affixed to the first heatercontact; a device body comprising; a cartridge receptacle for receivingthe cartridge; a second heater contact adapted to receive the firstheater contact and to complete a circuit; a power source connected tothe second heater contact; a printed circuit board (PCB) connected tothe power source and the second heater contact; wherein the PCB isconfigured to detect the absence of fluid based on the measuredresistance of the resistive heating element, and turn off the device.

The printed circuit board (PCB) may comprise a microcontroller;switches; circuitry comprising a reference resister; and an algorithmcomprising logic for control parameters; wherein the microcontrollercycles the switches at fixed intervals to measure the resistance of theresistive heating element relative to the reference resistor, andapplies the algorithm control parameters to control the temperature ofthe resistive heating element.

The micro-controller may instruct the device to turn itself off when theresistance exceeds the control parameter threshold indicating that theresistive heating element is dry.

In another aspect of the invention, a cartridge for a device forgenerating an inhalable aerosol may comprise: a fluid storagecompartment; a heater affixed to a first end comprising: a heaterchamber, a first pair of heater contacts, a fluid wick, and a resistiveheating element in contact with the wick; wherein the first pair ofheater contacts comprise thin plates affixed about the sides of theheater chamber, and wherein the fluid wick and resistive heating elementare suspended therebetween.

The first pair of heater contacts may further comprise: a formed shapethat comprises a tab having a flexible spring value that extends out ofthe heater to complete a circuit with the device body. The heatercontacts may be configured to mate with a second pair of heater contactsin a cartridge receptacle of the device body to complete a circuit. Thefirst pair of heater contacts may also be a heat sink that absorbs anddissipates excessive heat produced by the resistive heating element. Thefirst pair of heater contacts may be a heat shield that protect theheater chamber from excessive heat produced by the resistive heatingelement.

In another aspect of the invention, a cartridge for a device forgenerating an inhalable aerosol may comprise: a heater comprising; aheater chamber, a pair of thin plate heater contacts therein, a fluidwick positioned between the heater contacts, and a resistive heatingelement in contact with the wick; wherein the heater contacts eachcomprise a fixation site wherein the resistive heating element istensioned therebetween.

In another aspect of the invention, a cartridge for a device forgenerating an inhalable aerosol may comprise a heater, wherein theheater is attached to a first end of the cartridge.

The heater may enclose a first end of the cartridge and a first end ofthe fluid storage compartment. The heater may comprise more than onefirst condensation chamber. The heater may comprise a first condensationchamber. The condensation chamber may be formed along an exterior wallof the cartridge.

In another aspect of the invention, a cartridge for a device forgenerating an inhalable aerosol may comprise a fluid storagecompartment; and a mouthpiece, wherein the mouthpiece is attached to asecond end of the cartridge.

The mouthpiece may enclose a second end of the cartridge and a secondend of the fluid storage compartment. The mouthpiece may comprise asecond condensation chamber. The mouthpiece may comprise more than onesecond condensation chamber. The second condensation chamber may beformed along an exterior wall of the cartridge.

In an aspect of the invention, a cartridge for a device for generatingan inhalable aerosol may comprise: a fluid storage compartment; a heateraffixed to a first end; and a mouthpiece affixed to a second end;wherein the heater comprises a first condensation chamber and themouthpiece comprises a second condensation chamber.

The heater may comprise more than one first condensation chamber and themouthpiece comprises more than one second condensation chamber. Thefirst condensation chamber and the second condensation chamber may be influid communication. The mouthpiece may comprise an aerosol outlet influid communication with the second condensation chamber. The mouthpiecemay comprise two to more aerosol outlets. The cartridge may meet ISOrecycling standards. The cartridge may meet ISO recycling standards forplastic waste.

In an aspect of the invention, a device for generating an inhalableaerosol may comprise: a device body comprising a cartridge receptacle;and a detachable cartridge; wherein the cartridge receptacle and thedetachable cartridge form a separable coupling, wherein the separablecoupling comprises a friction assembly, a snap-fit assembly or amagnetic assembly.

In an aspect of the invention, a method of fabricating a device forgenerating an inhalable aerosol may comprise: providing a device bodycomprising a cartridge receptacle; and providing a detachable cartridge;wherein the cartridge receptacle and the detachable cartridge form aseparable coupling comprising a friction assembly, a snap-fit assemblyor a magnetic assembly.

In an aspect of the invention, a method of fabricating a cartridge for adevice for generating an inhalable aerosol may comprise: providing afluid storage compartment; affixing a heater to a first end with asnap-fit coupling; and affixing a mouthpiece to a second end with asnap-fit coupling.

In an aspect of the invention, A cartridge for a device for generatingan inhalable aerosol with an airflow path comprising: a channelcomprising a portion of an air inlet passage; a second air passage influid communication with the channel; a heater chamber in fluidcommunication with the second air passage; a first condensation chamberin fluid communication with the heater chamber; a second condensationchamber in fluid communication with the first condensation chamber; andan aerosol outlet in fluid communication with second condensationchamber.

In an aspect of the invention, a cartridge for a device for generatingan inhalable aerosol may comprise: a fluid storage compartment; a heateraffixed to a first end; and a mouthpiece affixed to a second end;wherein said mouthpiece comprises two or more aerosol outlets.

In an aspect of the invention, a system for providing power to anelectronic device for generating an inhalable vapor, the system maycomprise; a rechargeable power storage device housed within theelectronic device for generating an inhalable vapor; two or more pinsthat are accessible from an exterior surface of the electronic devicefor generating an inhalable vapor, wherein the charging pins are inelectrical communication with the rechargeable power storage device; acharging cradle comprising two or more charging contacts configured toprovided power to the rechargeable storage device, wherein the devicecharging pins are reversible such that the device is charged in thecharging cradle for charging with a first charging pin on the device incontact a first charging contact on the charging cradle and a secondcharging pin on the device in contact with second charging contact onthe charging cradle and with the first charging pin on the device incontact with second charging contact on the charging cradle and thesecond charging pin on the device in contact with the first chargingcontact on the charging cradle.

The charging pins may be visible on an exterior housing of the device.The user may permanently disable the device by opening the housing. Theuser may permanently destroy the device by opening the housing.

Additional aspects and advantages of the present disclosure will becomereadily apparent to those skilled in this art from the followingdetailed description, wherein only illustrative embodiments of thepresent disclosure are shown and described. As will be realized, thepresent disclosure is capable of other and different embodiments, andits several details are capable of modifications in various obviousrespects, all without departing from the disclosure. Accordingly, thedrawings and description are to be regarded as illustrative in nature,and not as restrictive.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in thisspecification are herein incorporated by reference to the same extent asif each individual publication, patent, or patent application wasspecifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity inthe appended claims. A better understanding of the features andadvantages of the present invention will be obtained by reference to thefollowing detailed description that sets forth illustrative embodiments,in which the principles of the invention are utilized, and theaccompanying drawings of which:

FIG. 1 is an illustrative cross-sectional view of an exemplaryvaporization device.

FIG. 2 is an illustrative cross-sectional view of an exemplaryvaporization device with various electronic features and valves.

FIG. 3 is an illustrative sectional view of another exemplaryvaporization device comprising a condensation chamber, air inlet andaeration vent in the mouthpiece.

FIGS. 4A-4C is an illustrative example of an oven section of anotherexemplary vaporization device configuration with a access lid,comprising an oven having an air inlet, air outlet, and an additionalaeration vent in the airflow pathway, after the oven.

FIG. 5 is an illustrative isometric view of an assembled inhalableaerosol device.

FIGS. 6A-6D are illustrative arrangements and section views of thedevice body and sub-components.

FIG. 7A is an illustrative isometric view of an assembled cartridge.

FIG. 7B is an illustrative exploded isometric view of a cartridgeassembly

FIG. 7C is a side section view of FIG. 3A illustrating the inletchannel, inlet hole and relative placement of the wick, resistiveheating element, and heater contacts, and the heater chamber inside ofthe heater.

FIG. 8A is an illustrative end section view of an exemplary cartridgeinside the heater.

FIG. 8B is an illustrative side view of the cartridge with the capremoved and heater shown in shadow/outline.

FIG. 9 is an illustrative sequence of the assembly method for thecartridge.

FIGS. 10A-10C are illustrative sequences showing the airflow/vapor pathfor the cartridge.

FIGS. 11-13 represent an illustrative assembly sequence for assemblingthe main components of the device.

FIG. 14 illustrates front, side and section views of the assembledinhalable aerosol device.

FIG. 15 is an illustrative view of an activated, assembled inhalableaerosol device.

FIG. 16A-16C are representative illustrations of a charging device forthe aerosol device and the application of the charger with the device.

FIG. 17A-17B are representative illustrations of aproportional-integral-derivative controller (PID) block diagram andcircuit diagram representing the essential components in a device tocontrol coil temperature.

FIG. 18 is a device with charging contacts visible from an exteriorhousing of the device.

FIG. 19 is an exploded view of a charging assembly of a device.

FIG. 20 is a detailed view of a charging assembly of a device.

FIG. 21 is a detailed view of charging pins in a charging assembly of adevice.

FIG. 22 is a device in a charging cradle.

FIG. 23 is a circuit provided on a PCB configured to permit a device tocomprise reversible charging contacts.

DETAILED DESCRIPTION OF THE INVENTION

Provided herein are systems and methods for generating a vapor from amaterial. The vapor may be delivered for inhalation by a user. Thematerial may be a solid, liquid, powder, solution, paste, gel, or any amaterial with any other physical consistency. The vapor may be deliveredto the user for inhalation by a vaporization device. The vaporizationdevice may be a handheld vaporization device. The vaporization devicemay be held in one hand by the user.

The vaporization device may comprise one or more heating elements theheating element may be a resistive heating element. The heating elementmay heat the material such that the temperature of the materialincreases. Vapor may be generated as a result of heating the material.Energy may be required to operate the heating element, the energy may bederived from a battery in electrical communication with the heatingelement. Alternatively a chemical reaction (e.g., combustion or otherexothermic reaction) may provide energy to the heating element.

One or more aspects of the vaporization device may be designed and/orcontrolled in order to deliver a vapor with one or more specifiedproperties to the user. For example, aspects of the vaporization devicethat may be designed and/or controlled to deliver the vapor withspecified properties may comprise the heating temperature, heatingmechanism, device air inlets, internal volume of the device, and/orcomposition of the material.

In some cases, a vaporization device may have an “atomizer” or“cartomizer” configured to heat an aerosol forming solution (e.g.,vaporizable material). The aerosol forming solution may compriseglycerin and/or propylene glycol. The vaporizable material may be heatedto a sufficient temperature such that it may vaporize.

An atomizer may be a device or system configured to generate an aerosol.The atomizer may comprise a small heating element configured to heatand/or vaporize at least a portion of the vaporizable material and awicking material that may draw a liquid vaporizable material in to theatomizer. The wicking material may comprise silica fibers, cotton,ceramic, hemp, stainless steel mesh, and/or rope cables. The wickingmaterial may be configured to draw the liquid vaporizable material in tothe atomizer without a pump or other mechanical moving part. Aresistance wire may be wrapped around the wicking material and thenconnected to a positive and negative pole of a current source (e.g.,energy source). The resistance wire may be a coil. When the resistancewire is activated the resistance wire (or coil) may have a temperatureincrease as a result of the current flowing through the resistive wireto generate heat. The heat may be transferred to at least a portion ofthe vaporizable material through conductive, convective, and/orradiative heat transfer such that at least a portion of the vaporizablematerial vaporizes.

Alternatively or in addition to the atomizer, the vaporization devicemay comprise a “cartomizer” to generate an aerosol from the vaporizablematerial for inhalation by the user. The cartomizer may comprise acartridge and an atomizer. The cartomizer may comprise a heating elementsurrounded by a liquid-soaked poly-foam that acts as holder for thevaporiable material (e.g., the liquid). The cartomizer may be reusable,rebuildable, refillable, and/or disposable. The cartomizer may be usedwith a tank for extra storage of a vaporizable material.

Air may be drawn into the vaporization device to carry the vaporizedaerosol away from the heating element, where it then cools and condensesto form liquid particles suspended in air, which may then be drawn outof the mouthpiece by the user.

The vaporization of at least a portion of the vaporizable material mayoccur at a lower temperatures in the vaporization device compared totemperatures required to generate an inhalable vapor in a cigarette. Acigarette may be a device in which a smokable material is burned togenerate an inhalable vapor. The lower temperature of the vaporizationdevice may result in less decomposition and/or reaction of the vaporizedmaterial, and therefore produce an aerosol with many fewer chemicalcomponents compared to a cigarette. In some cases, the vaporizationdevice may generate an aerosol with fewer chemical components that maybe harmful to human health compared to a cigarette. Additionally, thevaporization device aerosol particles may undergo nearly completeevaporation in the heating process, the nearly complete evaporation mayyield an average particle size (e.g., diameter) value that may besmaller than the average particle size in tobacco or botanical basedeffluent.

A vaporization device may be a device configured to extract forinhalation one or more active ingredients of plant material, tobacco,and/or a botanical, or other herbs or blends. A vaporization device maybe used with pure chemicals and/or humectants that may or may not bemixed with plant material. Vaporization may be alternative to burning(smoking) that may avoid the inhalation of many irritating and/or toxiccarcinogenic by-products which may result from the pyrolytic process ofburning tobacco or botanical products above 300° C. The vaporizationdevice may operate at a temperature at or below 300° C.

A vaporizer (e.g., vaporization device) may not have an atomizer orcartomizer. Instead the device may comprise an oven. The oven may be atleast partially closed. The oven may have a closable opening. The ovenmay be wrapped with a heating element, alternatively the heating elementmay be in thermal communication with the oven through another mechanism.A vaporizable material may be placed directly in the oven or in acartridge fitted in the oven. The heating element in thermalcommunication with the oven may heat a vaporizable material mass inorder to create a gas phase vapor. The heating element may heat thevaporizable material through conductive, convective, and/or radiativeheat transfer. The vapor may be released to a vaporization chamber wherethe gas phase vapor may condense, forming an aerosol cloud havingtypical liquid vapor particles with particles having a diameter ofaverage mass of approximately 1 micron or greater. In some cases thediameter of average mass may be approximately 0.1-1 micron.

A used herein, the term “vapor” may generally refer to a substance inthe gas phase at a temperature lower than its critical point. The vapormay be condensed to a liquid or to a solid by increasing its pressurewithout reducing the temperature.

As used herein, the term “aerosol” may generally refer to a colloid offine solid particles or liquid droplets in air or another gas. Examplesof aerosols may include clouds, haze, and smoke, including the smokefrom tobacco or botanical products. The liquid or solid particles in anaerosol may have varying diameters of average mass that may range frommonodisperse aerosols, producible in the laboratory, and containingparticles of uniform size; to polydisperse colloidal systems, exhibitinga range of particle sizes. As the sizes of these particles becomelarger, they have a greater settling speed which causes them to settleout of the aerosol faster, making the appearance of the aerosol lessdense and to shorten the time in which the aerosol will linger in air.Interestingly, an aerosol with smaller particles will appear thicker ordenser because it has more particles. Particle number has a much biggerimpact on light scattering than particle size (at least for theconsidered ranges of particle size), thus allowing for a vapor cloudwith many more smaller particles to appear denser than a cloud havingfewer, but larger particle sizes.

As used herein the term “humectant” may generally refer to as asubstance that is used to keep things moist. A humectant may attract andretain moisture in the air by absorption, allowing the water to be usedby other substances. Humectants are also commonly used in many tobaccosor botanicals and electronic vaporization products to keep productsmoist and as vapor-forming medium. Examples include propylene glycol,sugar polyols such as glycerol, glycerin, and honey.

Rapid Aeration

In some cases, the vaporization device may be configured to deliver anaerosol with a high particle density. The particle density of theaerosol may refer to the number of the aerosol droplets relative to thevolume of air (or other dry gas) between the aerosol droplets. A denseaerosol may easily be visible to a user. In some cases the user mayinhale the aerosol and at least a fraction of the aerosol particles mayimpinge on the lungs and/or mouth of the user. The user may exhaleresidual aerosol after inhaling the aerosol. When the aerosol is densethe residual aerosol may have sufficient particle density such that theexhaled aerosol is visible to the user. In some cases, a user may preferthe visual effect and/or mouth feel of a dense aerosol.

A vaporization device may comprise a vaporizable material. Thevaporizable material may be contained in a cartridge or the vaporizablematerial may be loosely placed in one or more cavities the vaporizationdevice. A heating element may be provided in the device to elevate thetemperature of the vaporizable material such that at least a portion ofthe vaporizable material forms a vapor. The heating element may heat thevaporizable material by convective heat transfer, conductive heattransfer, and/or radiative heat transfer. The heating element may heatthe cartridge and/or the cavity in which the vaporizable material isstored.

Vapor formed upon heating the vaporizable material may be delivered tothe user. The vapor may be transported through the device from a firstposition in the device to a second position in the device. In somecases, the first position may be a location where at least a portion ofthe vapor was generated, for example, the cartridge or cavity or an areaadjacent to the cartridge or cavity. The second position may be amouthpiece. The user may suck on the mouthpiece to inhale the vapor.

At least a fraction of the vapor may condense after the vapor isgenerated and before the vapor is inhaled by the user. The vapor maycondense in a condensation chamber. The condensation chamber may be aportion of the device that the vapor passes through before delivery tothe user. In some cases, the device may include at least one aerationvent, placed in the condensation chamber of the vaporization device. Theaeration vent may be configured to introduce ambient air (or other gas)into the vaporization chamber. The air introduced into the vaporizationchamber may have a temperature lower than the temperature of a gasand/or gas/vapor mixture in the condensation chamber. Introduction ofthe relatively lower temperature gas into the vaporization chamber mayprovide rapid cooling of the heated gas vapor mixture that was generatedby heating the vaporizable material. Rapid cooling of the gas vapormixture may generate a dense aerosol comprising a high concentration ofliquid droplets having a smaller diameter and/or smaller average masscompared to an aerosol that is not rapidly cooled prior to inhalation bythe user.

An aerosol with a high concentration of liquid droplets having a smallerdiameter and/or smaller average mass compared to an aerosol that is notrapidly cooled prior to inhalation by the user may be formed in atwo-step process. The first step may occur in the oven chamber where thevaporizable material (e.g., tobacco and/or botanical and humectantblend) may be heated to an elevated temperature. At the elevatedtemperature, evaporation may happen faster than at room temperature andthe oven chamber may fill with the vapor phase of the humectants. Thehumectant may continue to evaporate until the partial pressure of thehumectant is equal to the saturation pressure. At this point, the gas issaid to have a saturation ratio of 1 (S=P_(partial)/P_(sat)).

In the second step, the gas (e.g., vapor and air) may exit the oven andenter a condenser or condensation chamber and begin to cool. As the gasphase vapor cools, the saturation pressure may decrease. As thesaturation pressure decreases, the saturation ratio may increase and thevapor may begin to condense, forming droplets. In some devices, with theabsence of added cooling aeration, the cooling may be relatively slowersuch that high saturation pressures may not be reached, and the dropletsthat form in the devices without added cooling aeration may berelatively larger and fewer in numbers. When cooler air is introduced, atemperature gradient may be formed between the cooler air and therelatively warmer gas in the device. Mixing between the cooler air andthe relatively warmer gas in a confined space inside of the vaporizationdevice may lead to rapid cooling. The rapid cooling may generate highsaturation ratios, small particles, and high concentrations of smallerparticles, forming a thicker, denser vapor cloud compared to particlesgenerated in a device without the aeration vents.

For the purpose of this disclosure, when referring to ratios ofhumectants such as vegetable glycerol or propylene glycol, “about” meansa variation of 5%, 10%, 20% or 25% depending on the embodiment.

For the purpose of this disclosure, when referring to a diameter ofaverage mass in particle sizes, “about” means a variation of 5%, 10%,20% or 25% depending on the embodiment.

A vaporization device configured to rapidly cool a vapor may comprise: amouthpiece comprising an aerosol outlet at a first end of the device; anoven comprising an oven chamber and a heater for heating a vapor formingmedium in the oven chamber and for forming a vapor therein; a condensercomprising a condensation chamber in which the vapor forms the inhalableaerosol; an air inlet that originates a first airflow path that includesthe oven chamber and then the condensation chamber, an aeration ventthat originates a second airflow path that joins the first airflow pathprior to or within the condensation chamber after the vapor is formed inthe oven chamber, wherein the joined first airflow path and secondairflow path are configured to deliver the inhalable aerosol formed inthe condensation chamber through the aerosol outlet of the mouthpiece toa user.

In some embodiments, the oven is within a body of the device. The ovenchamber may comprise an oven chamber inlet and an oven chamber outlet.The oven may further comprise a first valve at the oven chamber inlet,and a second valve at the oven chamber outlet.

The oven may be contained within a device housing. In some cases thebody of the device may comprise the aeration vent and/or the condenser.The body of the device may comprise one or more air inlets. The body ofthe device may comprise a housing that holds and/or at least partiallycontains one or more elements of the device.

The mouthpiece may be connected to the body. The mouthpiece may beconnected to the oven. The mouthpiece may be connected to a housing thatat least partially encloses the oven. In some cases, the mouthpiece maybe separable from the oven, the body, and/or the housing that at leastpartially encloses the oven. The mouthpiece may comprise at least one ofthe air inlet, the aeration vent, and the condenser. The mouthpiece maybe integral to the body of the device. The body of the device maycomprise the oven.

In some cases, the one or more aeration vents may comprise a valve. Thevalve may regulate a flow rate of air entering the device through theaeration vent. The valve may be controlled through a mechanical and/orelectrical control system.

A vaporization device configured to rapidly cool a vapor may comprise: abody, a mouthpiece, an aerosol outlet, a condenser with a condensationchamber, a heater, an oven with an oven chamber, a primary airflowinlet, and at least one aeration vent provided in the body, downstreamof the oven, and upstream of the mouthpiece.

FIG. 1 shows an example of a vaporization device configured to rapidlycool a vapor. The device 100, may comprise a body 101. The body mayhouse and/or integrate with one or more components of the device. Thebody may house and/or integrate with a mouthpiece 102. The mouthpiece102 may have an aerosol outlet 122. A user may inhale the generatedaerosol through the aerosol outlet 122 on the mouthpiece 102. The bodymay house and/or integrate with an oven region 104. The oven region 104may comprise an oven chamber where vapor forming medium 106 may beplaced. The vapor forming medium may include tobacco and/or botanicals,with or without a secondary humectant. In some cases the vapor formingmedium may be contained in a removable and/or refillable cartridge.

Air may be drawn into the device through a primary air inlet 121. Theprimary air inlet 121 may be on an end of the device 100 opposite themouthpiece 102. Alternatively, the primary air inlet 121 may be adjacentto the mouthpiece 102. In some cases, a pressure drop sufficient to pullair into the device through the primary air inlet 121 may be due to auser puffing on the mouthpiece 102.

The vapor forming medium (e.g., vaporizable material) may be heated inthe oven chamber by a heater 105, to generate elevated temperature gasphases (vapor) of the tobacco or botanical and humectant/vapor formingcomponents. The heater 105 may transfer heat to the vapor forming mediumthrough conductive, convective, and/or radiative heat transfer. Thegenerated vapor may be drawn out of the oven region and into thecondensation chamber 103 a, of the condenser 103 where the vapors maybegin to cool and condense into micro-particles or droplets suspended inair, thus creating the initial formation of an aerosol, before beingdrawn out of the mouthpiece through the aerosol outlet 122.

In some cases, relatively cooler air may be introduced into thecondensation chamber 103 a, through an aeration vent 107 such that thevapor condenses more rapidly compared to a vapor in a device without theaeration vent 107. Rapidly cooling the vapor may create a denser aerosolcloud having particles with a diameter of average mass of less than orequal to about 1 micron, and depending on the mixture ratio of thevapor-forming humectant, particles with a diameter of average mass ofless than or equal to about 0.5 micron

In another aspect, the present invention provides a device forgenerating an inhalable aerosol said device comprising a body with amouthpiece at one end, an attached body at the other end comprising acondensation chamber, a heater, an oven, wherein the oven comprises afirst valve in the airflow path at the primary airflow inlet of the ovenchamber, and a second valve at the outlet end of the oven chamber, andat least one aeration vent provided in the body, downstream of the oven,and upstream of the mouthpiece.

FIG. 2 shows a diagram of an alternative embodiment of the vaporizationdevice 200. The vaporization device may have a body 201. The body 201may integrate with and/or contain one or more components of the device.The body may integrate with or be connected to a mouthpiece 202

The body may comprise an oven region 204, with an oven chamber 204 ahaving a first constricting valve 208 in the primary air inlet of theoven chamber and a second constricting valve 209 at the oven chamberoutlet. The oven chamber 204 a may be sealed with a tobacco or botanicaland/or humectant/vapor forming medium 206 therein. The seal may be anair tight and/or liquid tight seal. The heater may be provided to theoven chamber with a heater 205. The heater 205 may be in thermalcommunication with the oven, for example the heater may be surroundingthe oven chamber during the vaporization process. Heater may contact theoven. The heater may be wrapped around the oven. Before inhalation andbefore air is drawn in through a primary air inlet 221, pressure maybuild in the sealed oven chamber as heat is continually added. Thepressure may build due to a phase change of the vaporizable material.Elevated temperature gas phases (vapor) of the tobacco or botanical andhumectant/vapor forming components may be achieved by continually addingheat to the oven. This heated pressurization process may generate evenhigher saturation ratios when the valves 208, 209 are opened duringinhalation. The higher saturation ratios may cause relatively higherparticle concentrations of gas phase humectant in the resultant aerosol.When the vapor is drawn out of the oven region and into the condensationchamber 203 a of the condenser 203, for example by inhalation by theuser, the gas phase humectant vapors may be exposed to additional airthrough an aeration vent 207, and the vapors may begin to cool andcondense into droplets suspended in air. As described previously theaerosol may be drawn through the mouthpiece 222 by the user. Thiscondensation process may be further refined by adding an additionalvalve 210, to the aeration vent 207 to further control the air-vapormixture process.

FIG. 2 also illustrates an exemplary embodiment of the additionalcomponents which would be found in a vaporizing device, including apower source or battery 211, a printed circuit board 212, a temperatureregulator 213, and operational switches (not shown), housed within aninternal electronics housing 214, to isolate them from the damagingeffects of the moisture in the vapor and/or aerosol. The additionalcomponents may be found in a vaporizing device that may or may notcomprise an aeration vent as described above.

In some embodiments of the vaporization device, components of the deviceare user serviceable, such as the power source or battery. Thesecomponents may be replaceable or rechargeable.

In yet another aspect, the invention provides a device for generating aninhalable aerosol said device comprising a first body, a mouthpiecehaving an aerosol outlet, a condensation chamber within a condenser andan airflow inlet and channel, an attached second body, comprising aheater and oven with an oven chamber, wherein said airflow channel isupstream of the oven and the mouthpiece outlet to provide airflowthrough the device, across the oven, and into the condensation chamberwhere an auxiliary aeration vent is provided.

FIG. 3 shows a section view of a vaporization device 300. The device 300may comprise a body 301. The body may be connected to or integral with amouthpiece 302 at one end. The mouthpiece may comprise a condensationchamber 303 a within a condenser section 303 and an airflow inlet 321and air channel 323. The device body may comprise a proximally locatedoven 304 comprising an oven chamber 304 a. The oven chamber may be inthe body of the device. A vapor forming medium 306 (e.g., vaporizablematerial) comprising tobacco or botanical and humectant vapor formingmedium may be placed in the oven. The vapor forming medium may be indirect contact with an air channel 323 from the mouthpiece. The tobaccoor botanical may be heated by heater 305 surrounding the oven chamber,to generate elevated temperature gas phases (vapor) of the tobacco orbotanical and humectant/vapor forming components and air drawn inthrough a primary air inlet 321, across the oven, and into thecondensation chamber 303 a of the condenser region 303 due to a userpuffing on the mouthpiece. Once in the condensation chamber where thegas phase humectant vapors begin to cool and condense into dropletssuspended in air, additional air is allowed to enter through aerationvent 307, thus, once again creating a denser aerosol cloud havingparticles with a diameter of average mass of less than a typicalvaporization device without an added aeration vent, before being drawnout of the mouthpiece through the aerosol outlet 322.

In some aspects of the invention, the device comprises a mouthpiececomprising an aerosol outlet at a first end of the device and an airinlet that originates a first airflow path; an oven comprising an ovenchamber that is in the first airflow path and includes the oven chamberand a heater for heating a vapor forming medium in the oven chamber andfor forming a vapor therein, a condenser comprising a condensationchamber in which the vapor forms the inhalable aerosol, an aeration ventthat originates a second airflow path that allows air from the aerationvent to join the first airflow path prior to or within the condensationchamber and downstream from the oven chamber thereby forming a joinedpath, wherein the joined path is configured to deliver the inhalableaerosol formed in the condensation chamber through the aerosol outlet ofthe mouthpiece to a user.

In some aspects of the invention, the device may comprise a mouthpiececomprising an aerosol outlet at a first end of the device, an air inletthat originates a first airflow path, and an aeration vent thatoriginates a second airflow path that allows air from the aeration ventto join the first airflow path; an oven comprising an oven chamber thatis in the first airflow path and includes the oven chamber and a heaterfor heating a vapor forming medium in the oven chamber and for forming avapor therein, a condenser comprising a condensation chamber in whichthe vapor forms the inhalable aerosol and wherein air from the aerationvent joins the first airflow path prior to or within the condensationchamber and downstream from the oven chamber thereby forming a joinedpath, wherein the joined path is configured to deliver the inhalableaerosol through the aerosol outlet of the mouthpiece to a user, asillustrated in exemplary FIG. 3.

In some aspects of the invention, the device may comprise a body withone or more separable components. For example, the mouthpiece may beseparably attached to the body comprising the condensation chamber, aheater, and an oven, as illustrated in exemplary FIG. 1 or 2.

In some aspects of the invention, the device may comprise a body withone or more separable components. For example, the mouthpiece may beseparably attached to the body. The mouthpiece may comprise thecondensation chamber, and may be attached to or immediately adjacent tothe oven and which is separable from the body comprising a heater, andthe oven, as illustrated in exemplary FIG. 3.

In other aspects of the invention, the at least one aeration vent may belocated in the condensation chamber of the condenser, as illustrated inexemplary FIG. 1, 2, or 3. The at least one aeration vent may comprise athird valve in the airflow path of the at least one aeration vent, asillustrated in exemplary FIG. 2. The first, second and third valve is acheck valve, a clack valve, a non-return valve, or a one-way valve. Inany of the preceding aspects of the invention, the first, second orthird valve may be mechanically actuated, electronically actuated ormanually actuated. One skilled in the art will recognize after readingthis disclosure that this device may be modified in a way such that anyone, or each of these openings or vents could be configured to have adifferent combination or variation of mechanisms as described to controlairflow, pressure and temperature of the vapor created and aerosol beinggenerated by these device configurations, including a manually operatedopening or vent with or without a valve.

In some embodiments of the invention, the device may further comprise atleast one of: a power source, a printed circuit board, a switch, and atemperature regulator. Alternately, one skilled in the art wouldrecognize that each configuration previously described will alsoaccommodate said power source (battery), switch, printed circuit board,or temperature regulator as appropriate, in the body.

In some embodiments of the invention, the device may be disposable whenthe supply of pre-packaged aerosol-forming media is exhausted.Alternatively, the device may be rechargeable such that the battery maybe rechargeable or replaceable, and/or the aerosol-forming media may berefilled, by the user/operator of the device. Still further, in otherembodiments of the invention, the device may be rechargeable such thatthe battery may be rechargeable or replaceable, and/or the operator mayalso add or refill a tobacco or botanical component, in addition to arefillable or replaceable aerosol-forming media to the device.

As illustrated in FIG. 1, 2 or 3, in some embodiments of the invention,the vaporization device comprises tobacco or a botanical heated in saidoven chamber, wherein said tobacco or botanical further compriseshumectants to produce an aerosol comprising gas phase components of thehumectant and tobacco or botanical. In some embodiments of theinvention, the gas phase humectant and tobacco or botanical vaporproduced by said heated aerosol forming media 106, 206, 306 is furthermixed with air from a special aeration vent 107, 207, 307 after exitingthe oven area 104, 204, 304 and entering a condensation chamber 103 a,203 a, 303 a to cool and condense said gas phase vapors to produce a fardenser, thicker aerosol comprising more particles than would haveotherwise been produced without the extra cooling air, with a diameterof average mass of less than or equal to about 1 micron.

In other embodiments of the invention, each aerosol configurationproduced by mixing the gas phase vapors with the cool air may comprise adifferent range of particles, for example; with a diameter of averagemass of less than or equal to about 0.9 micron; less than or equal toabout 0.8 micron; less than or equal to about 0.7 micron; less than orequal to about 0.6 micron; and even an aerosol comprising particlediameters of average mass of less than or equal to about 0.5 micron.

The possible variations and ranges of aerosol density are great in thatthe possible number of combinations of temperature, pressure, tobacco orbotanical choices and humectant selections are numerous. However, byexcluding the tobacco or botanical choices and limiting the temperaturesranges and the humectant ratios to those described herein, the inventorhas demonstrated that this device will produce a far denser, thickeraerosol comprising more particles than would have otherwise beenproduced without the extra cooling air, with a diameter of average massof less than or equal to about 1 micron.

In some embodiments of the invention, the humectant comprises glycerolor vegetable glycerol as a vapor-forming medium.

In still other embodiments of the invention, the humectant comprisespropylene glycol as a vapor-forming medium.

In preferred embodiments of the invention, the humectant may comprise aratio of vegetable glycerol to propylene glycol as a vapor-formingmedium. The ranges of said ratio may vary between a ratio of about 100:0vegetable glycerol to propylene glycol and a ratio of about 50:50vegetable glycerol to propylene glycol. The difference in preferredratios within the above stated range may vary by as little as 1, forexample, said ratio may be about 99:1 vegetable glycerol to propyleneglycol. However, more commonly said ratios would vary in increments ofabout 5, for example, about 95:5 vegetable glycerol to propylene glycol;or about 85:15 vegetable glycerol to propylene glycol; or about 55:45vegetable glycerol to propylene glycol.

In a preferred embodiment the ratio for the vapor forming medium will bebetween the ratios of about 80:20 vegetable glycerol to propyleneglycol, and about 60:40 vegetable glycerol to propylene glycol.

In a most preferred embodiment, the ratio for the vapor forming mediumwill be about 70:30 vegetable glycerol to propylene glycol.

In any of the preferred embodiments, the humectant may further compriseflavoring products. These flavorings may include enhancers comprisingcocoa solids, licorice, tobacco or botanical extracts, and varioussugars, to name but a few.

In some embodiments of the invention, the tobacco or botanical is heatedin the oven up to its pyrolytic temperature, which as noted previouslyis most commonly measured in the range of 300-1000° C.

In preferred embodiments, the tobacco or botanical is heated to about300° C. at most. In other preferred embodiments, the tobacco orbotanical is heated to about 200° C. at most. In still other preferredembodiments, the tobacco or botanical is heated to about 160° C. atmost. It should be noted that in these lower temperature ranges (<300°C.), pyrolysis of tobacco or botanical does not typically occur, yetvapor formation of the tobacco or botanical components and flavoringproducts does occur. In addition, vapor formation of the components ofthe humectant, mixed at various ratios will also occur, resulting innearly complete vaporization, depending on the temperature, sincepropylene glycol has a boiling point of about 180°-190° C. and vegetableglycerin will boil at approximately 280°-290° C.

In still other preferred embodiments, the aerosol produced by saidheated tobacco or botanical and humectant is mixed with air providedthrough an aeration vent.

In still other preferred embodiments, the aerosol produced by saidheated tobacco or botanical and humectant mixed with air, is cooled to atemperature of about 50°-70° C. at most, and even as low as 35° C.before exiting the mouthpiece, depending on the air temperature beingmixed into the condensation chamber. In some embodiments, thetemperature is cooled to about 35°-55° C. at most, and may have afluctuating range of ± about 10° C. or more within the overall range ofabout 35°-70° C.

In yet another aspect, the invention provides a vaporization device forgenerating an inhalable aerosol comprising a unique oven configuration,wherein said oven comprises an access lid and an auxiliary aeration ventlocated within the airflow channel immediately downstream of the ovenand before the aeration chamber. In this configuration, the user maydirectly access the oven by removing the access lid, providing the userwith the ability to recharge the device with vaporization material.

In addition, having the added aeration vent in the airflow channelimmediately after the oven and ahead of the vaporization chamberprovides the user with added control over the amount of air entering theaeration chamber downstream and the cooling rate of the aerosol beforeit enters the aeration chamber.

As noted in FIGS. 4A-4C, the device 400 may comprise a body 401, havingan air inlet 421 allowing initial air for the heating process into theoven region 404. After heating the tobacco or botanical, and humectant(heater not shown), the gas phase humectant vapor generated may traveldown the airflow channel 423, passing the added aeration vent 407wherein the user may selectively increase airflow into the heated vapor.The user may selectively increase and/or decrease the airflow to theheated vapor by controlling a valve in communication with the aerationvent 407. In some cases, the device may not have an aeration vent.Airflow into the heated vapor through the aeration vent may decrease thevapor temperature before exiting the airflow channel at the outlet 422,and increase the condensation rate and vapor density by decreasing thediameter of the vapor particles within the aeration chamber (not shown),thus producing a thicker, denser vapor compared to the vapor generatedby a device without the aeration vent. The user may also access the ovenchamber 404 a to recharge or reload the device 400, through an accesslid 430 provided therein, making the device user serviceable. The accesslid may be provided on a device with or without an aeration vent.

Provided herein is a method for generating an inhalable aerosol, themethod comprising: providing an vaporization device, wherein said deviceproduces a vapor comprising particle diameters of average mass of about1 micron or less, wherein the vapor is formed by heating a vapor formingmedium in an oven chamber of the device to a first temperature below thepyrolytic temperature of the vapor forming medium, and cooling the vaporin a condensation chamber to a temperature below the first temperature,before exiting an aerosol outlet of said device.

In some embodiments the vapor may be cooled by mixing relatively coolerair with the vapor in the condensation chamber during the condensationphase, after leaving the oven, where condensation of the gas phasehumectants occurs more rapidly due to high saturation ratios beingachieved at the moment of aeration, producing a higher concentration ofsmaller particles, with fewer by-products, in a denser aerosol, thanwould normally occur in a standard vaporization or aerosol generatingdevice.

In some embodiments, formation of an inhalable aerosol is a two stepprocess. The first step occurs in the oven where the tobacco orbotanical and humectant blend is heated to an elevated temperature. Atthe elevated temperature, evaporation happens faster than at roomtemperature and the oven chamber fills with the vapor phase of thehumectants. The humectant will continue to evaporate until the partialpressure of the humectant is equal to the saturation pressure. At thispoint, the gas is said to have a saturation ratio of 1(S=P_(partial)/P_(sat)).

In the second step, the gas leaves the oven chamber, passes to acondensation chamber in a condenser and begins to cool. As the gas phasevapor cools, the saturation pressure also goes down, causing thesaturation ratio to rise, and the vapor to condensate, forming droplets.When cooling air is introduced, the large temperature gradient betweenthe two fluids mixing in a confined space leads to very rapid cooling,causing high saturation ratios, small particles, and higherconcentrations of smaller particles, forming a thicker, denser vaporcloud.

Provided herein is a method for generating an inhalable aerosolcomprising: a vaporization device having a body with a mouthpiece at oneend, and an attached body at the other end comprising; a condenser witha condensation chamber, a heater, an oven with an oven chamber, and atleast one aeration vent provided in the body, downstream of the oven,and upstream of the mouthpiece, wherein tobacco or botanical comprisinga humectant is heated in said oven chamber to produce a vapor comprisinggas phase humectants.

As previously described, a vaporization device having an auxiliaryaeration vent located in the condensation chamber capable of supplyingcool air (relative to the heated gas components) to the gas phase vaporsand tobacco or botanical components exiting the oven region, may beutilized to provide a method for generating a far denser, thickeraerosol comprising more particles than would have otherwise beenproduced without the extra cooling air, with a diameter of average massof less than or equal to about 1 micron.

In another aspect, provided herein is a method for generating aninhalable aerosol comprising: a vaporization device, having a body witha mouthpiece at one end, and an attached body at the other endcomprising: a condenser with a condensation chamber, a heater, an ovenwith an oven chamber, wherein said oven chamber further comprises afirst valve in the airflow path at the inlet end of the oven chamber,and a second valve at the outlet end of the oven chamber; and at leastone aeration vent provided in said body, downstream of the oven, andupstream of the mouthpiece wherein tobacco or botanical comprising ahumectant is heated in said oven chamber to produce a vapor comprisinggas phase humectants.

As illustrated in exemplary FIG. 2, by sealing the oven chamber 204 awith a tobacco or botanical and humectant vapor forming medium 206therein, and applying heat with the heater 205 during the vaporizationprocess, before inhalation and air is drawn in through a primary airinlet 221, the pressure will build in the oven chamber as heat iscontinually added with an electronic heating circuit generated throughthe combination of the battery 211, printed circuit board 212,temperature regulator 213, and operator controlled switches (not shown),to generate even greater elevated temperature gas phase humectants(vapor) of the tobacco or botanical and humectant vapor formingcomponents. This heated pressurization process generates even highersaturation ratios when the valves 208, 209 are opened during inhalation,which cause higher particle concentrations in the resultant aerosol,when the vapor is drawn out of the oven region and into the condensationchamber 203 a, where they are again exposed to additional air through anaeration vent 207, and the vapors begin to cool and condense intodroplets suspended in air, as described previously before the aerosol iswithdrawn through the mouthpiece 222. The inventor also notes that thiscondensation process may be further refined by adding an additionalvalve 210, to the aeration vent 207 to further control the air-vapormixture process.

In some embodiments of any one of the inventive methods, the first,second and/or third valve is a one-way valve, a check valve, a clackvalve, or a non-return valve. The first, second and/or third valve maybe mechanically actuated. The first, second and/or third valve may beelectronically actuated. The first, second and/or third valve may beautomatically actuated. The first, second and/or third valve may bemanually actuated either directly by a user or indirectly in response toan input command from a user to a control system that actuates thefirst, second and/or third valve.

In other aspects of the inventive methods, said device further comprisesat least one of: a power source, a printed circuit board, or atemperature regulator.

In any of the preceding aspects of the inventive method, one skilled inthe art will recognize after reading this disclosure that this methodmay be modified in a way such that any one, or each of these openings orvents could be configured to have a different combination or variationof mechanisms or electronics as described to control airflow, pressureand temperature of the vapor created and aerosol being generated bythese device configurations, including a manually operated opening orvent with or without a valve.

The possible variations and ranges of aerosol density are great in thatthe possible number of temperature, pressure, tobacco or botanicalchoices and humectant selections and combinations are numerous. However,by excluding the tobacco or botanical choices and limiting thetemperatures to within the ranges and the humectant ratios describedherein, the inventor has demonstrated a method for generating a fardenser, thicker aerosol comprising more particles than would haveotherwise been produced without the extra cooling air, with a diameterof average mass of less than or equal to 1 micron.

In some embodiments of the inventive methods, the humectant comprises aratio of vegetable glycerol to propylene glycol as a vapor-formingmedium. The ranges of said ratio will vary between a ratio of about100:0 vegetable glycerol to propylene glycol and a ratio of about 50:50vegetable glycerol to propylene glycol. The difference in preferredratios within the above stated range may vary by as little as 1, forexample, said ratio may be about 99:1 vegetable glycerol to propyleneglycol. However, more commonly said ratios would vary in increments of5, for example, about 95:5 vegetable glycerol to propylene glycol; orabout 85:15 vegetable glycerol to propylene glycol; or about 55:45vegetable glycerol to propylene glycol.

Because vegetable glycerol is less volatile than propylene glycol, itwill recondense in greater proportions. A humectant with higherconcentrations of glycerol will generate a thicker aerosol. The additionof propylene glycol will lead to an aerosol with a reduced concentrationof condensed phase particles and an increased concentration of vaporphase effluent. This vapor phase effluent is often perceived as a tickleor harshness in the throat when the aerosol is inhaled. To someconsumers, varying degrees of this sensation may be desirable. The ratioof vegetable glycerol to propylene glycol may be manipulated to balanceaerosol thickness with the right amount of “throat tickle.”

In a preferred embodiment of the method, the ratio for the vapor formingmedium will be between the ratios of about 80:20 vegetable glycerol topropylene glycol, and about 60:40 vegetable glycerol to propyleneglycol.

In a most preferred embodiment of the method, the ratio for the vaporforming medium will be about 70:30 vegetable glycerol to propyleneglycol. On will envision that there will be blends with varying ratiosfor consumers with varying preferences.

In any of the preferred embodiments of the method, the humectant furthercomprises flavoring products. These flavorings include enhancers such ascocoa solids, licorice, tobacco or botanical extracts, and varioussugars, to name a few.

In some embodiments of the method, the tobacco or botanical is heated toits pyrolytic temperature.

In preferred embodiments of the method, the tobacco or botanical isheated to about 300° C. at most.

In other preferred embodiments of the method, the tobacco or botanicalis heated to about 200° C. at most. In still other embodiments of themethod, the tobacco or botanical is heated to about 160° C. at most.

As noted previously, at these lower temperatures, (<300° C.), pyrolysisof tobacco or botanical does not typically occur, yet vapor formation ofthe tobacco or botanical components and flavoring products does occur.As may be inferred from the data supplied by Baker et al., an aerosolproduced at these temperatures is also substantially free from Hoffmananalytes or at least 70% less Hoffman analytes than a common tobacco orbotanical cigarette and scores significantly better on the Ames testthan a substance generated by burning a common cigarette. In addition,vapor formation of the components of the humectant, mixed at variousratios will also occur, resulting in nearly complete vaporization,depending on the temperature, since propylene glycol has a boiling pointof about 180°-190° C. and vegetable glycerin will boil at approximately280°-290° C.

In any one of the preceding methods, said inhalable aerosol produced bytobacco or a botanical comprising a humectant and heated in said ovenproduces an aerosol comprising gas phase humectants is further mixedwith air provided through an aeration vent.

In any one of the preceding methods, said aerosol produced by saidheated tobacco or botanical and humectant mixed with air, is cooled to atemperature of about 50°-70° C., and even as low as 35° C., beforeexiting the mouthpiece. In some embodiments, the temperature is cooledto about 35°-55° C. at most, and may have a fluctuating range of ± about10° C. or more within the overall range of about 35°-70° C.

In some embodiments of the method, the vapor comprising gas phasehumectant may be mixed with air to produce an aerosol comprisingparticle diameters of average mass of less than or equal to about 1micron.

In other embodiments of the method, each aerosol configuration producedby mixing the gas phase vapors with the cool air may comprise adifferent range of particles, for example; with a diameter of averagemass of less than or equal to about 0.9 micron; less than or equal toabout 0.8 micron; less than or equal to about 0.7 micron; less than orequal to about 0.6 micron; and even an aerosol comprising particlediameters of average mass of less than or equal to about 0.5 micron.

Cartridge Design and Vapor Generation from Material in Cartridge

In some cases, a vaporization device may be configured to generate aninhalable aerosol. A device may be a self-contained vaporization device.The device may comprise an elongated body which functions to complementaspects of a separable and recyclable cartridge with air inlet channels,air passages, multiple condensation chambers, flexible heater contacts,and multiple aerosol outlets. Additionally, the cartridge may beconfigured for ease of manufacture and assembly.

Provided herein is a vaporization device for generating an inhalableaerosol. The device may comprise a device body, a separable cartridgeassembly further comprising a heater, at least one condensation chamber,and a mouthpiece. The device provides for compact assembly anddisassembly of components with detachable couplings; overheat shut-offprotection for the resistive heating element; an air inlet passage (anenclosed channel) formed by the assembly of the device body and aseparable cartridge; at least one condensation chamber within theseparable cartridge assembly; heater contacts; and one or morerefillable, reusable, and/or recyclable components.

Provided herein is a device for generating an inhalable aerosolcomprising: a device body comprising a cartridge receptacle; a cartridgecomprising: a storage compartment, and a channel integral to an exteriorsurface of the cartridge, and an air inlet passage formed by the channeland an internal surface of the cartridge receptacle when the cartridgeis inserted into the cartridge receptacle. The cartridge may be formedfrom a metal, plastic, ceramic, and/or composite material. The storagecompartment may hold a vaporizable material. FIG. 7A shows an example ofa cartridge 30 for use in the device. The vaporizable material may be aliquid at or near room temperature. In some cases the vaporizablematerial may be a liquid below room temperature. The channel may form afirst side of the air inlet passage, and an internal surface of thecartridge receptacle may form a second side of the air inlet passage, asillustrated in various non-limiting aspects of FIGS. 5-6D, 7C,8A, 8B,and 10A

Provided herein is a device for generating an inhalable aerosol. Thedevice may comprise a body that houses, contains, and or integrates withone or more components of the device. The device body may comprise acartridge receptacle. The cartridge receptacle may comprise a channelintegral to an interior surface of the cartridge receptacle; and an airinlet passage formed by the channel and an external surface of thecartridge when the cartridge is inserted into the cartridge receptacle.A cartridge may be fitted and/or inserted into the cartridge receptacle.The cartridge may have a fluid storage compartment. The channel may forma first side of the air inlet passage, and an external surface of thecartridge forms a second side of the air inlet passage. The channel maycomprise at least one of: a groove; a trough; a track; a depression; adent; a furrow; a trench; a crease; and a gutter. The integral channelmay comprise walls that are either recessed into the surface or protrudefrom the surface where it is formed. The internal side walls of thechannel may form additional sides of the air inlet passage. The channelmay have a round, oval, square, rectangular, or other shaped crosssection. The channel may have a closed cross section. The channel may beabout 0.1 cm, 0.5 cm, 1 cm, 2 cm, or 5 cm wide. The channel may be about0.1 mm, 0.5 mm, 1 mm, 2 mm, or 5 mm deep. The channel may be about 0.1cm, 0.5 cm, 1 cm, 2 cm, or 5 cm long. There may be at least 1 channel.

In some embodiments, the cartridge may further comprise a second airpassage in fluid communication with the air inlet passage to the fluidstorage compartment, wherein the second air passage is formed throughthe material of the cartridge.

FIGS. 5-7C show various views of a compact electronic device assembly 10for generating an inhalable aerosol. The compact electronic device 10may comprise a device body 20 with a cartridge receptacle 21 forreceiving a cartridge 30. The device body may have a square orrectangular cross section. Alternatively, the cross section of the bodymay be any other regular or irregular shape. The cartridge receptaclemay be shaped to receive an opened cartridge 30 a or “pod”. Thecartridge may be opened when a protective cap is removed from a surfaceof the cartridge. In some cases, the cartridge may be opened when a holeor opening is formed on a surface of the cartridge. The pod 30 a may beinserted into an open end of the cartridge receptacle 21 so that anexposed first heater contact tips 33 a on the heater contacts 33 of thepod make contact with the second heater contacts 22 of the device body,thus forming the device assembly 10.

Referring to FIG. 14, it is apparent in the plan view that when the pod30 a is inserted into the notched body of the cartridge receptacle 21,the channel air inlet 50 is left exposed. The size of the channel airinlet 50 may be varied by altering the configuration of the notch in thecartridge receptacle 21.

The device body may further comprise a rechargeable battery, a printedcircuit board (PCB) 24 containing a microcontroller with the operatinglogic and software instructions for the device, a pressure switch 27 forsensing the user's puffing action to activate the heater circuit, anindicator light 26, charging contacts (not shown), and an optionalcharging magnet or magnetic contact (not shown). The cartridge mayfurther comprise a heater 36. The heater may be powered by therechargeable battery. The temperature of the heater may be controlled bythe microcontroller. The heater may be attached to a first end of thecartridge.

In some embodiments, the heater may comprise a heater chamber 37, afirst pair of heater contacts 33, 33′, a fluid wick 34, and a resistiveheating element 35 in contact with the wick. The first pair of heatercontacts may comprise thin plates affixed about the sides of the heaterchamber. The fluid wick and resistive heating element may be suspendedbetween the heater contacts.

In some embodiments, there may be two or more resistive heating elements35, 35′ and two or more wicks 34, 34′. In some of the embodiments, theheater contact 33 may comprise: a flat plate; a male contact; a femalereceptacle, or both; a flexible contact and/or copper alloy or anotherelectrically conductive material. The first pair of heater contacts mayfurther comprise a formed shape that may comprise a tab (e.g., flange)having a flexible spring value that extends out of the heater tocomplete a circuit with the device body. The first pair of heatercontact may be a heat sink that absorb and dissipate excessive heatproduced by the resistive heating element. Alternatively, the first pairof heater contacts may be a heat shield that protects the heater chamberfrom excessive heat produced by the resistive heating element. The firstpair of heater contacts may be press-fit to an attachment feature on theexterior wall of the first end of the cartridge. The heater may enclosea first end of the cartridge and a first end of the fluid storagecompartment.

As illustrated in the exploded assembly of FIG. 7B, a heater enclosuremay comprises two or more heater contacts 33, each comprising a flatplate which may be machined or stamped from a copper alloy or similarelectrically conductive material. The flexibility of the tip is providedby the cut-away clearance feature 33 b created below the male contactpoint tip 33 a which capitalizes on the inherent spring capacity of themetal sheet or plate material. Another advantage and improvement of thistype of contact is the reduced space requirement, simplifiedconstruction of a spring contact point (versus a pogo pin) and the easyof assembly. The heater may comprise a first condensation chamber. Theheater may comprise more one or more additional condensation chambers inaddition to the first condensation chamber. The first condensationchamber may be formed along an exterior wall of the cartridge.

In some cases, the cartridge (e.g., pod) is configured for ease ofmanufacturing and assembly. The cartridge may comprise an enclosure. Theenclosure may be a tank. The tank may comprise an interior fluid storagecompartment 32. The interior fluid storage compartment 32 which is openat one or both ends and comprises raised rails on the side edges 45 band 46 b. The cartridge may be formed from plastic, metal, composite,and/or a ceramic material. The cartridge may be rigid or flexible.

The tank may further comprise a set of first heater contact plates 33formed from copper alloy or another electrically conductive material,having a thin cut-out 33 b below the contact tips 33 a (to create aflexible tab) which are affixed to the sides of the first end of thetank and straddle the open-sided end 53 of the tank. The plates mayaffix to pins, or posts as shown in FIG. 7B or 5, or may be attached byother common means such as compression beneath the enclosure 36. A fluidwick 34 having a resistive heating element 35 wrapped around it, isplaced between the first heater contact plates 33, and attached thereto.A heater 36, comprising raised internal edges on the internal end (notshown), a thin mixing zone (not shown), and primary condensation channelcovers 45 a that slide over the rails 45 b on the sides of the tank onthe first half of the tank, creating a primary condensationchannel/chamber 45. In addition, a small male snap feature 39 b locatedat the end of the channel cover is configured fall into a female snapfeature 39 a, located mid-body on the side of the tank, creating asnap-fit assembly.

As will be further clarified below, the combination of the open-sidedend 53, the protruding tips 33 a of the contact plates 33, the fluidwick 34 having a resistive heating element 35, enclosed in the open endof the fluid storage tank, under the heater 36, with a thin mixing zonetherein, creates a efficient heater system. In addition, the primarycondensation channel covers 45 a which slide over the rails 45 b on thesides of the tank create an integrated, easily assembled, primarycondensation chamber 45, all within the heater at the first end of thecartridge 30 or pod 30 a.

In some embodiments of the device, as illustrated in FIG. 9, the heatermay encloses at least a first end of the cartridge. The enclosed firstend of the cartridge may include the heater and the interior fluidstorage compartment. In some embodiments, the heater further comprisesat least one first condensation chamber 45.

FIG. 9 shows diagramed steps that mat be performed to assemble acartomizer and/or mouthpiece. In A-B the fluid storage compartment 32 amay be oriented such that the heater inlet 53 faces upward. The heatercontacts 33 may be inserted into the fluid storage compartment. Flexibletabs 33 a may be inserted into the heater contacts 33. In a step D theresistive heating element 35 may be wound on to the wick 34. In step Ethe wick 34 and heater 35 may be placed on the fluid storagecompartment. One or more free ends of the heater may sit outside theheater contacts. The one or more free ends may be soldered in place,rested in a groove, or snapped into a fitted location. At least afraction of the one or more free ends may be in communication with theheater contacts 33. In a step F the heater enclosure 36 may be snappedin place. The heater enclosure 36 may be fitted on the fluid storagecompartment. Step G shows the heater enclosure 36 is in place on thefluid storage compartment. In step H the fluid storage compartment canbe flipped over. In step I the mouthpiece 31 can be fitted on the fluidstorage compartment. Step J shows the mouthpiece 31 in place on thefluid storage compartment. In step K an end 49 can be fitted on thefluid storage compartment opposite the mouthpiece. Step L shows a fullyassembled cartridge 30. FIG. 7B shows an exploded view of the assembledcartridge 30.

Depending on the size of the heater and/or heater chamber, the heatermay have more than one wick 34 and resistive heating element 35.

In some embodiments, the first pair of heater contacts 33 furthercomprises a formed shape that comprises a tab 33 a having a flexiblespring value that extends out of the heater. In some embodiments, thecartridge 30 comprises heater contacts 33 which are inserted into thecartridge receptacle 21 of the device body 20 wherein, the flexible tabs33 a insert into a second pair of heater contacts 22 to complete acircuit with the device body. The first pair of heater contacts 33 maybe a heat sink that absorbs and dissipates excessive heat produced bythe resistive heating element 35. The first pair of heater contacts 33may be a heat shield that protects the heater chamber from excessiveheat produced by the resistive heating element 35. The first pair ofheater contacts may be press-fit to an attachment feature on theexterior wall of the first end of the cartridge. The heater 36 mayenclose a first end of the cartridge and a first end of the fluidstorage compartment 32 a. The heater may comprise a first condensationchamber 45. The heater may comprise at least one additional condensationchamber 45, 45′, 45″, etc. The first condensation chamber may be formedalong an exterior wall of the cartridge.

In still other embodiments of the device, the cartridge may furthercomprise a mouthpiece 31, wherein the mouthpiece comprises at least oneaerosol outlet channel/secondary condensation chamber 46; and at leastone aerosol outlet 47. The mouthpiece may be attached to a second end ofthe cartridge. The second end of the cartridge with the mouthpiece maybe exposed when the cartridge is inserted in the device. The mouthpiecemay comprise more than one second condensation chamber 46, 46′, 46″,etc. The second condensation chamber is formed along an exterior wall ofthe cartridge.

The mouthpiece 31 may enclose the second end of the cartridge andinterior fluid storage compartment. The partially assembled (e.g.,mouthpiece removed) unit may be inverted and filled with a vaporizablefluid through the opposite, remaining (second) open end. Once filled, asnap-on mouthpiece 31 that also closes and seals the second end of thetank is inserted over the end. It also comprises raised internal edges(not shown), and aerosol outlet channel covers 46 a that may slide overthe rails 46 b located on the sides of the second half of the tank,creating aerosol outlet channels/secondary condensation chambers 46. Theaerosol outlet channels/secondary condensation chambers 46 slide overthe end of primary condensation chamber 45, at a transition area 57, tocreate a junction for the vapor leaving the primary chamber and proceedout through the aerosol outlets 47, at the end of the aerosol outletchannels 46 and user-end of the mouthpiece 31.

The cartridge may comprise a first condensation chamber and a secondcondensation chamber 45, 46. The cartridge may comprise more than onefirst condensation chamber and more than one second condensation chamber45, 46, 45′, 46′, etc.

In some embodiments of the device, a first condensation chamber 45 maybe formed along the outside of the cartridge fluid storage compartment31. In some embodiments of the device an aerosol outlet 47 exists at theend of aerosol outlet chamber 46. In some embodiments of the device, afirst and second condensation chamber 45, 46 may be formed along theoutside of one side of the cartridge fluid storage compartment 31. Insome embodiments the second condensation chamber may be an aerosoloutlet chamber. In some embodiments another pair of first and/or secondcondensation chambers 45′, 46′ is formed along the outside of thecartridge fluid storage compartment 31 on another side of the device. Insome embodiments another aerosol outlet 47′ will also exist at the endof the second pair of condensation chambers 45′, 46′.

In any one of the embodiments, the first condensation chamber and thesecond condensation chamber may be in fluid communication as illustratedin FIG. 10C.

In some embodiments, the mouthpiece may comprise an aerosol outlet 47 influid communication with the second condensation chamber 46. Themouthpiece may comprise more than one aerosol outlet 47, 47′ in fluidcommunication with more than one the second condensation chamber 46,46′. The mouthpiece may enclose a second end of the cartridge and asecond end of the fluid storage compartment.

In each of the embodiments described herein, the cartridge may comprisean airflow path comprising: an air inlet passage; a heater; at least afirst condensation chamber; an aerosol outlet chamber, and an outletport. In some of the embodiments described herein, the cartridgecomprises an airflow path comprising: an air inlet passage; a heater; afirst condensation chamber; a secondary condensation chamber; and anoutlet port.

In still other embodiments described herein the cartridge may comprisean airflow path comprising at least one air inlet passage; a heater; atleast one first condensation chamber; at least one secondarycondensation chamber; and at least one outlet port.

As illustrated in FIGS. 10A-10C, an airflow path is created when theuser draws on the mouthpiece 31 to create a suction (e.g., a puff),which essentially pulls air through the channel air inlet opening 50,through the air inlet passage 51, and into the heater chamber 37 throughthe second air passage (tank air inlet hole) 41 at the tank air inlet52, then into the heater inlet 53. At this point, the pressure sensorhas sensed the user's puff, and activated the circuit to the resistiveheating element 35, which in turn, begins to generate vapor from thevapor fluid (e-juice). As air enters the heater inlet 53, it begins tomix and circulate in a narrow chamber above and around the wick 34 andbetween the heater contacts 33, generating heat, and dense, concentratedvapor as it mixes in the flow path 54 created by the sealing structureobstacles 44. FIG. 8A shows a detailed view of the sealing structureobstacles 44. Ultimately the vapor may be drawn, out of the heater alongan airpath 55 near the shoulder of the heater and into the primarycondensation chamber 45 where the vapor expands and begins to cool. Asthe expanding vapor moves along the airflow path, it makes a transitionfrom the primary condensation chamber 45 through a transition area 57,creating a junction for the vapor leaving the primary chamber, andentering the second vapor chamber 46, and proceeds out through theaerosol outlets 47, at the end of the mouthpiece 31 to the user.

As illustrated in FIGS. 10A-10C, the device may have a dual set of airinlet passages 50-53, dual first condensation chambers 55/45, dualsecond condensation chambers and aeration channels 57/46, and/or dualaerosol outlet vents 47.

Alternatively, the device may have an airflow path comprising: an airinlet passage 50, 51; a second air passage 41; a heater chamber 37; afirst condensation chamber 45; a second condensation chamber 46; and/oran aerosol outlet 47.

In some cases, the devise may have an airflow path comprising: more thanone air inlet passage; more than one second air passage; a heaterchamber; more than one first condensation chamber; more than one secondcondensation chamber; and more than one aerosol outlet as clearlyillustrated in FIGS. 10A-10C.

In any one of the embodiments described herein, the heater 36 may be influid communication with the internal fluid storage compartment 32 a.

In each of the embodiments described herein, the fluid storagecompartment 32 is in fluid communication with the heater chamber 37,wherein the fluid storage compartment is capable of retaining condensedaerosol fluid, as illustrated in FIGS. 10A, 10C and 14.

In some embodiments of the device, the condensed aerosol fluid maycomprise a nicotine formulation. In some embodiments, the condensedaerosol fluid may comprise a humectant. In some embodiments, thehumectant may comprise propylene glycol. In some embodiments, thehumectant may comprise vegetable glycerin.

In some cases, the cartridge may be detachable from the device body. Insome embodiments, the cartridge receptacle and the detachable cartridgemay form a separable coupling. In some embodiments the separablecoupling may comprise a friction assembly. As illustrated in FIGS.11-14, the device may have a press-fit (friction) assembly between thecartridge pod 30 a and the device receptacle. Additionally, adent/friction capture such as 43 may be utilized to capture the pod 30 ato the device receptacle or to hold a protective cap 38 on the pod, asfurther illustrated in FIG. 8B.

In other embodiments, the separable coupling may comprise a snap-fit orsnap-lock assembly. In still other embodiments the separable couplingmay comprise a magnetic assembly.

In any one of the embodiments described herein, the cartridge componentsmay comprise a snap-fit or snap-lock assembly, as illustrated in FIG. 5.In any one of the embodiments, the cartridge components may be reusable,refillable, and/or recyclable. The design of these cartridge componentslend themselves to the use of such recyclable plastic materials aspolypropylene, for the majority of components.

In some embodiments of the device 10, the cartridge 30 may comprise: afluid storage compartment 32; a heater 36 affixed to a first end with asnap-fit coupling 39 a, 39 b; and a mouthpiece 31 affixed to a secondend with a snap-fit coupling 39 c, 39 d (not shown—but similar to 39 aand 39 b). The heater 36 may be in fluid communication with the fluidstorage compartment 32. The fluid storage compartment may be capable ofretaining condensed aerosol fluid. The condensed aerosol fluid maycomprise a nicotine formulation. The condensed aerosol fluid maycomprise a humectant. The humectant may comprise propylene glycol and/orvegetable glycerin.

Provided herein is a device for generating an inhalable aerosolcomprising: a device body 20 comprising a cartridge receptacle 21 forreceiving a cartridge 30; wherein an interior surface of the cartridgereceptacle forms a first side of an air inlet passage 51 when acartridge comprising a channel integral 40 to an exterior surface isinserted into the cartridge receptacle 21, and wherein the channel formsa second side of the air inlet passage 51.

Provided herein is a device for generating an inhalable aerosolcomprising: a device body 20 comprising a cartridge receptacle 21 forreceiving a cartridge 30; wherein the cartridge receptacle comprises achannel integral to an interior surface and forms a first side of an airinlet passage when a cartridge is inserted into the cartridgereceptacle, and wherein an exterior surface of the cartridge forms asecond side of the air inlet passage 51.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising: a fluid storage compartment 32; achannel integral 40 to an exterior surface, wherein the channel forms afirst side of an air inlet passage 51; and wherein an internal surfaceof a cartridge receptacle 21 in the device forms a second side of theair inlet passage 51 when the cartridge is inserted into the cartridgereceptacle.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising a fluid storage compartment 32, whereinan exterior surface of the cartridge forms a first side of an air inletchannel 51 when inserted into a device body 10 comprising a cartridgereceptacle 21, and wherein the cartridge receptacle further comprises achannel integral to an interior surface, and wherein the channel forms asecond side of the air inlet passage 51.

In some embodiments, the cartridge further comprises a second airpassage 41 in fluid communication with the channel 40, wherein thesecond air passage 41 is formed through the material of the cartridge 32from an exterior surface of the cartridge to the internal fluid storagecompartment 32 a.

In some embodiments of the device body cartridge receptacle 21 or thecartridge 30, the integral channel 40 comprises at least one of: agroove; a trough; a depression; a dent; a furrow; a trench; a crease;and a gutter.

In some embodiments of the device body cartridge receptacle 21 or thecartridge 30, the integral channel 40 comprises walls that are eitherrecessed into the surface or protrude from the surface where it isformed.

In some embodiments of the device body cartridge receptacle 21 or thecartridge 30, the internal side walls of the channel 40 form additionalsides of the air inlet passage 51.

Provided herein is a device for generating an inhalable aerosolcomprising: a cartridge comprising; a fluid storage compartment; aheater affixed to a first end comprising; a first heater contact, aresistive heating element affixed to the first heater contact; a devicebody comprising; a cartridge receptacle for receiving the cartridge; asecond heater contact adapted to receive the first heater contact and tocomplete a circuit; a power source connected to the second heatercontact; a printed circuit board (PCB) connected to the power source andthe second heater contact; wherein the PCB is configured to detect theabsence of fluid based on the measured resistance of the resistiveheating element, and turn off the device.

Referring now to FIGS. 13, 14, and 15, in some embodiments, the devicebody further comprises at least one: second heater contact 22 (bestshown in FIG. 6C detail); a battery 23; a printed circuit board 24; apressure sensor 27; and an indicator light 26.

In some embodiments, the printed circuit board (PCB) further comprises:a microcontroller; switches; circuitry comprising a reference resister;and an algorithm comprising logic for control parameters; wherein themicrocontroller cycles the switches at fixed intervals to measure theresistance of the resistive heating element relative to the referenceresistor, and applies the algorithm control parameters to control thetemperature of the resistive heating element.

As illustrated in the basic block diagram of FIG. 17A, the deviceutilizes a proportional-integral-derivative controller or PID controllaw. A PID controller calculates an “error” value as the differencebetween a measured process variable and a desired setpoint. When PIDcontrol is enabled, power to the coil is monitored to determine whetheror not acceptable vaporization is occurring. With a given airflow overthe coil, more power will be required to hold the coil at a giventemperature if the device is producing vapor (heat is removed from thecoil to form vapor). If power required to keep the coil at the settemperature drops below a threshold, the device indicates that it cannotcurrently produce vapor. Under normal operating conditions, thisindicates that there is not enough liquid in the wick for normalvaporization to occur.

In some embodiments, the micro-controller instructs the device to turnitself off when the resistance exceeds the control parameter thresholdindicating that the resistive heating element is dry.

In still other embodiments, the printed circuit board further compriseslogic capable of detecting the presence of condensed aerosol fluid inthe fluid storage compartment and is capable of turning off power to theheating contact(s) when the condensed aerosol fluid is not detected.When the microcontroller is running the PID temperature controlalgorithm 70, the difference between a set point and the coiltemperature (error) is used to control power to the coil so that thecoil quickly reaches the set point temperature, [between 200° C. and400° C.]. When the over-temperature algorithm is used, power is constantuntil the coil reaches an over-temperature threshold, [between 200° C.and 400° C.]; (FIG. 17 A applies: set point temperature isover-temperature threshold; constant power until error reaches 0).

The essential components of the device used to control the resistiveheating element coil temperature are further illustrated in the circuitdiagram of FIG. 17B. Wherein, BATT 23 is the battery; MCU 72 is themicrocontroller; Q1 (76) and Q2 (77) are P-channel MOSFETs (switches);R_COIL 74 is the resistance of the coil. R_REF 75 is a fixed referenceresistor used to measure R_COIL 74 through a voltage divider 73.

The battery powers the microcontroller. The microcontroller turns on Q2for 1 ms every 100 ms so that the voltage between R_REF and R_COIL (avoltage divider) may be measured by the MCU at V_MEAS. When Q2 is off,the control law controls Q1 with PWM (pulse width modulation) to powerthe coil (battery discharges through Q1 and R_COIL when Q1 is on).

In some embodiments of the device, the device body further comprises atleast one: second heater contact; a power switch; a pressure sensor; andan indicator light.

In some embodiments of the device body, the second heater contact 22 maycomprise: a female receptacle; or a male contact, or both, a flexiblecontact; or copper alloy or another electrically conductive material.

In some embodiments of the device body, the battery supplies power tothe second heater contact, pressure sensor, indicator light and theprinted circuit board. In some embodiments, the battery is rechargeable.In some embodiments, the indicator light 26 indicates the status of thedevice and/or the battery or both.

In some embodiments of the device, the first heater contact and thesecond heater contact complete a circuit that allows current to flowthrough the heating contacts when the device body and detachablecartridge are assembled, which may be controlled by an on/off switch.Alternatively, the device can be turned on an off by a puff sensor. Thepuff sensor may comprise a capacitive membrane. The capacitive membranemay be similar to a capacitive membrane used in a microphone.

In some embodiments of the device, there is also an auxiliary chargingunit for recharging the battery 23 in the device body. As illustrated inFIGS. 16A-16C, the charging unit 60, may comprise a USB device with aplug for a power source 63 and protective cap 64, with a cradle 61 forcapturing the device body 20 (with or without the cartridge installed).The cradle may further comprise either a magnet or a magnetic contact 62to securely hold the device body in place during charging. Asillustrated in FIG. 6B, the device body further comprises a matingcharging contact 28 and a magnet or magnetic contact 29 for theauxiliary charging unit. FIG. 16C is an illustrative example of thedevice 20 being charged in a power source 65 (laptop computer ortablet).

In some cases the microcontroller on the PCB may be configured tomonitor the temperature of the heater such that the vaporizable materialis heated to a prescribed temperature. The prescribed temperature may bean input provided by the user. A temperature sensor may be incommunication with the microcontroller to provide an input temperatureto the microcontroller for temperature regulation. A temperature sensormay be a thermistor, thermocouple, thermometer, or any other temperaturesensors. In some cases, the heating element may simultaneously performas both a heater and a temperature sensor. The heating element maydiffer from a thermistor by having a resistance with a relatively lowerdependence on temperature. The heating element may comprise a resistancetemperature detector.

The resistance of the heating element may be an input to themicrocontroller. In some cases, the resistance may be determined by themicrocontroller based on a measurement from a circuit with a resistorwith at least one known resistance, for example, a Wheatstone bridge.Alternatively, the resistance of the heating element may be measuredwith a resistive voltage divider in contact with the heating element anda resistor with a known and substantially constant resistance. Themeasurement of the resistance of the heating element may be amplified byan amplifier. The amplifier may be a standard op amp or instrumentationamplifier. The amplified signal may be substantially free of noise. Insome cases, a charge time for a voltage divider between the heatingelement and a capacitor may be determined to calculate the resistance ofthe heating element. In some cases, the microcontroller must deactivatethe heating element during resistance measurements. The resistance ofthe heating element may be directly proportional to the temperature ofthe heating element such that the temperature may be directly determinefrom the resistance measurement. Determining the temperature directlyfrom the heating element resistance measurement rather than from anadditional temperature sensor may generate a more accurate measurementbecause unknown contact thermal resistance between the temperaturesensor and the heating element is eliminated. Additionally, thetemperature measurement may be determined directly and therefore fasterand without a time lag associated with attaining equilibrium between theheating element and a temperature sensor in contact with the heatingelement.

Provided herein is a device for generating an inhalable aerosolcomprising: a cartridge comprising a first heater contact; a device bodycomprising; a cartridge receptacle for receiving the cartridge; a secondheater contact adapted to receive the first heater contact and tocomplete a circuit; a power source connected to the second heatercontact; a printed circuit board (PCB) connected to the power source andthe second heater contact; and a single button interface; wherein thePCB is configured with circuitry and an algorithm comprising logic for achild safety feature.

In some embodiments, the algorithm requires a code provided by the userto activate the device. In some embodiments; the code is entered by theuser with the single button interface. In still further embodiments thesingle button interface is the also the power switch.

Provided herein is a cartridge 30 for a device 10 for generating aninhalable aerosol comprising: a fluid storage compartment 32; a heater36 affixed to a first end comprising: a heater chamber 37, a first pairof heater contacts 33, a fluid wick 34, and a resistive heating element35 in contact with the wick; wherein the first pair of heater contacts33 comprise thin plates affixed about the sides of the heater chamber37, and wherein the fluid wick 34 and resistive heating element 35 aresuspended therebetween.

Depending on the size of the heater or heater chamber, the heater mayhave more than one wick 34, 34′ and resistive heating element 35, 35′.

In some embodiments, the first pair of heater contacts further comprisea formed shape that comprises a tab 33 a having a flexible spring valuethat extends out of the heater 36 to complete a circuit with the devicebody 20.

In some embodiments, the heater contacts 33 are configured to mate witha second pair of heater contacts 22 in a cartridge receptacle 21 of thedevice body 20 to complete a circuit.

In some embodiments, the first pair of heater contacts is also a heatsink that absorbs and dissipates excessive heat produced by theresistive heating element.

In some embodiments, the first pair of heater contacts is a heat shieldthat protects the heater chamber from excessive heat produced by theresistive heating element.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising: a heater 36 comprising; a heaterchamber 37, a pair of thin plate heater contacts 33 therein, a fluidwick 34 positioned between the heater contacts 33, and a resistiveheating element 35 in contact with the wick; wherein the heater contacts33 each comprise a fixation site 33 c wherein the resistive heatingelement 35 is tensioned therebetween.

As will be obvious to one skilled in the art after reviewing theassembly method illustrated in FIG. 9, the heater contacts 33 simplysnap or rest on locator pins on either side of the air inlet 53 on thefirst end of the cartridge interior fluid storage compartment, creatinga spacious vaporization chamber containing the at least one wick 34 andat least one heating element 35.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising a heater 36 attached to a first end ofthe cartridge.

In some embodiments, the heater encloses a first end of the cartridgeand a first end of the fluid storage compartment 32, 32 a.

In some embodiments, the heater comprises a first condensation chamber45.

In some embodiments, the heater comprises more than one firstcondensation chamber 45, 45′.

In some embodiments, the condensation chamber is formed along anexterior wall of the cartridge 45 b.

As noted previously, and described in FIGS. 10A, 10B and 10C, theairflow path through the heater and heater chamber generates vaporwithin the heater circulating airpath 54, which then exits through theheater exits 55 into a first (primary) condensation chamber 45, which isformed by components of the tank body comprising the primarycondensation channel/chamber rails 45 b, the primary condensationchannel cover 45 a, (the outer side wall of the heater enclosure).

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising a fluid storage compartment 32 and amouthpiece 31, wherein the mouthpiece is attached to a second end of thecartridge and further comprises at least one aerosol outlet 47.

In some embodiments, the mouthpiece 31 encloses a second end of thecartridge 30 and a second end of the fluid storage compartment 32, 32 a.

Additionally, as clearly illustrated in FIG. 10C in some embodiments themouthpiece also contains a second condensation chamber 46 prior to theaerosol outlet 47, which is formed by components of the tank body 32comprising the secondary condensation channel/chamber rails 46 b, thesecond condensation channel cover 46 a, (the outer side wall of themouthpiece). Still further, the mouthpiece may contain yet anotheraerosol outlet 47′ and another (second) condensation chamber 46′ priorto the aerosol outlet, on another side of the cartridge.

In other embodiments, the mouthpiece comprises more than one secondcondensation chamber 46, 46′.

In some preferred embodiments, the second condensation chamber is formedalong an exterior wall of the cartridge 46 b.

In each of the embodiments described herein, the cartridge 30 comprisesan airflow path comprising: an air inlet channel and passage 40, 41, 42;a heater chamber 37; at least a first condensation chamber 45; and anoutlet port 47. In some of the embodiments described herein, thecartridge 30 comprises an airflow path comprising: an air inlet channeland passage 40, 41, 42; a heater chamber 37; a first condensationchamber 45; a second condensation chamber 46; and an outlet port 47.

In still other embodiments described herein the cartridge 30 maycomprise an airflow path comprising at least one air inlet channel andpassage 40, 41, 42; a heater chamber 37; at least one first condensationchamber 45; at least one second condensation chamber 46; and at leastone outlet port 47.

In each of the embodiments described herein, the fluid storagecompartment 32 is in fluid communication with the heater 36, wherein thefluid storage compartment is capable of retaining condensed aerosolfluid.

In some embodiments of the device, the condensed aerosol fluid comprisesa nicotine formulation. In some embodiments, the condensed aerosol fluidcomprises a humectant. In some embodiments, the humectant comprisespropylene glycol. In some embodiments, the humectant comprises vegetableglycerin.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 comprising: a fluid storage compartment 32; aheater 36 affixed to a first end; and a mouthpiece 31 affixed to asecond end; wherein the heater comprises a first condensation chamber 45and the mouthpiece comprises a second condensation chamber 46.

In some embodiments, the heater comprises more than one firstcondensation chamber 45, 45′ and the mouthpiece comprises more than onesecond condensation chamber 46, 46′.

In some embodiments, the first condensation chamber and the secondcondensation chamber are in fluid communication. As illustrated in FIG.10C, the first and second condensation chambers have a common transitionarea 57, 57′, for fluid communication.

In some embodiments, the mouthpiece comprises an aerosol outlet 47 influid communication with the second condensation chamber 46.

In some embodiments, the mouthpiece comprises two or more aerosoloutlets 47, 47′.

In some embodiments, the mouthpiece comprises two or more aerosoloutlets 47, 47′ in fluid communication with the two or more secondcondensation chambers 46, 46′.

In any one of the embodiments, the cartridge meets ISO recyclingstandards.

In any one of the embodiments, the cartridge meets ISO recyclingstandards for plastic waste.

And in still other embodiments, the plastic components of the cartridgeare composed of polylactic acid (PLA), wherein the PLA components arecompostable and or degradable.

Provided herein is a device for generating an inhalable aerosol 10comprising a device body 20 comprising a cartridge receptacle 21; and adetachable cartridge 30; wherein the cartridge receptacle and thedetachable cartridge form a separable coupling, and wherein theseparable coupling comprises a friction assembly, a snap-fit assembly ora magnetic assembly.

In other embodiments of the device, the cartridge is a detachableassembly. In any one of the embodiments described herein, the cartridgecomponents may comprise a snap-lock assembly such as illustrated by snapfeatures 39 a and 39 b. In any one of the embodiments, the cartridgecomponents are recyclable.

Provided herein is a method of fabricating a device for generating aninhalable aerosol comprising: providing a device body comprising acartridge receptacle; and providing a detachable cartridge; wherein thecartridge receptacle and the detachable cartridge form a separablecoupling comprising a friction assembly, a snap-fit assembly or amagnetic assembly when the cartridge is inserted into the cartridgereceptacle.

Provided herein is a method of making a device 10 for generating aninhalable aerosol comprising: providing a device body 20 with acartridge receptacle 21 comprising one or more interior couplingsurfaces 21 a, 21 b, 21 c . . . ; and further providing a cartridge 30comprising: one or more exterior coupling surfaces 36 a, 36 b, 36 c, . .. , a second end and a first end; a tank 32 comprising an interior fluidstorage compartment 32 a; at least one channel 40 on at least oneexterior coupling surface, wherein the at least one channel forms oneside of at least one air inlet passage 51, and wherein at least oneinterior wall of the cartridge receptacle forms at least one side oneside of at least one air inlet passage 51 when the detachable cartridgeis inserted into the cartridge receptacle.

FIG. 9 provides an illustrative example of a method of assembling such adevice.

In some embodiments of the method, the cartridge 30 is assembled with a[protective] removable end cap 38 to protect the exposed heater contacttabs 33 a protruding from the heater 36.

Provided herein is a method of fabricating a cartridge for a device forgenerating an inhalable aerosol comprising: providing a fluid storagecompartment; affixing a heater to a first end with a snap-fit coupling;and affixing a mouthpiece to a second end with a snap-fit coupling.

Provided herein is a cartridge 30 for a device for generating aninhalable aerosol 10 with an airflow path comprising: a channel 50comprising a portion of an air inlet passage 51; a second air passage 41in fluid communication with the channel; a heater chamber 37 in fluidcommunication with the second air passage; a first condensation chamber45 in fluid communication with the heater chamber; a second condensationchamber 46 in fluid communication with the first condensation chamber;and an aerosol outlet 47 in fluid communication with second condensationchamber.

Provided herein is a device 10 for generating an inhalable aerosoladapted to receive a removable cartridge 30, wherein the cartridgecomprises a fluid storage compartment [or tank] 32; an air inlet 41; aheater 36, a [protective] removable end cap 38, and a mouthpiece 31.

Charging

In some cases, the vaporization device may comprise a power source. Thepower source may be configured to provide power to a control system, oneor more heating elements, one or more sensors, one or more lights, oneor more indicators, and/or any other system on the electronic cigarettethat requires a power source. The power source may be an energy storagedevice. The power source may be a battery or a capacitor. In some cases,the power source may be a rechargeable battery.

The battery may be contained within a housing of the device. In somecases the battery may be removed from the housing for charging.Alternatively, the battery may remain in the housing while the batteryis being charged. Two or more charge contact may be provided on anexterior surface of the device housing. The two or more charge contactsmay be in electrical communication with the battery such that thebattery may be charged by applying a charging source to the two or morecharge contacts without removing the battery from the housing.

FIG. 18 shows a device 1800 with charge contacts 1801. The chargecontacts 1801 may be accessible from an exterior surface of a devicehousing 1802. The charge contacts 1801 may be in electricalcommunication with an energy storage device (e.g., battery) inside ofthe device housing 1802. In some cases, the device housing may notcomprise an opening through which the user may access components in thedevice housing. The user may not be able to remove the battery and/orother energy storage device from the housing. In order to open thedevice housing a user must destroy or permanently disengage the chargecontacts. In some cases, the device may fail to function after a userbreaks open the housing.

FIG. 19 shows an exploded view of a charging assembly 1900 in anelectronic vaporization device. The housing (not shown) has been removedfrom the exploded view in FIG. 19. The charge contact pins 1901 may bevisible on the exterior of the housing. The charge contact pins 1901 maybe in electrical communication with a power storage device of theelectronic vaporization device. When the device is connected to a powersource (e.g., during charging of the device) the charging pins mayfacilitate electrical communication between the power storage deviceinside of the electronic vaporization device and the power sourceoutside of the housing of the vaporization device. The charge contactpins 1901 may be held in place by a retaining bezel 1902. The chargecontact pins 1901 may be in electrical communication with a charger flex1903. The charging pins may contact the charger flex such that a needfor soldering of the charger pins to an electrical connection to be inelectrical communication with the power source may be eliminated. Thecharger flex may be soldered to a printed circuit board (PCB). Thecharger flex may be in electrical communication with the power storagedevice through the PCB. The charger flex may be held in place by a bentspring retainer 1904.

FIG. 20 shows the bent spring retainer in an initial position 2001 and adeflected position 2002. The bent spring retainer may hold the retainingbezel in a fixed location. The bent spring retainer may deflect only inone direction when the charging assembly is enclosed in the housing ofthe electronic vaporization device.

FIG. 21 shows a location of the charger pins 2101 when the electronicvaporization device is fully assembled with the charging pins 2101contact the charging flex 2102. When the device is fully assembled atleast a portion of the retaining bezel may be fitted in an indentation2103 on the inside of the housing 2104. In some cases, disassembling theelectronic vaporization device may destroy the bezel such that thedevice cannot be reassembled after disassembly.

A user may place the electronic smoking device in a charging cradle. Thecharging cradle may be a holder with charging contact configured to mateor couple with the charging pins on the electronic smoking device toprovide charge to the energy storage device in the electronicvaporization device from a power source (e.g., wall outlet, generator,and/or external power storage device). FIG. 22 shows a device 2302 in acharging cradle 2301. The charging cable may be connected to a walloutlet, USB, or any other power source. The charging pins (not shown) onthe device 2302 may be connected to charging contacts (not shown) on thecharging cradle 2301. The device may be configured such that when thedevice is placed in the cradle for charging a first charging pin on thedevice may contact a first charging contact on the charging cradle and asecond charging pin on the device may contact a second charging contacton the charging cradle or the first charging pin on the device maycontact a second charging contact on the charging cradle and the secondcharging pin on the device may contact the first charging contact on thecharging cradle. The charging pins on the device and the chargingcontacts on the cradle may be in contact in any orientation. Thecharging pins on the device and the charging contacts on the cradle maybe agnostic as to whether they are current inlets or outlets. Each ofthe charging pins on the device and the charging contacts on the cradlemay be negative or positive. The charging pins on the device may bereversible.

FIG. 23 shows a circuit 2400 that may permit the charging pins on thedevice to be reversible. The circuit 2400 may be provided on a PCB inelectrical communication with the charging pins. The circuit 2400 maycomprise a metal—oxide—semiconductor field-effect transistor (MOSFET) Hbridge. The MOSFET H bridge may rectify a change in voltage across thecharging pins when the charging pins are reversed from a firstconfiguration where in a first configuration the device is placed in thecradle for charging with the first charging pin on the device in contactwith the first charging contact on the charging cradle to a secondcharging pin on the device in contact with the second charging contacton the charging cradle to a second configuration where the firstcharging pin on the device is in contact with the second chargingcontact on the charging cradle and the second charging pin on the deviceis in contact with the first charging contact on the charging cradle.The MOSFET H bridge may rectify the change in voltage with an efficientcurrent path.

As shown in FIG. 23 the MOSFET H bridge may comprise two or moren-channel MOSFETs and two or more p-channel MOSFETs. The n-channel andp-channel MOSFETs may be arranged in an H bridge. Sources of p-channelsMOSFETs (Q1 and Q3) may be in electrical communication. Similarly,sources of n-channel FETs (Q2 and Q4) may be in electricalcommunication. Drains of pairs of n and p MOSFETs (Q1 with Q2 and Q3with Q4) may be in electrical communication. TA common drain from one nand p pair may be in electrical communication with one or more gates ofthe other n and p pair and/or vice versa. Charge contacts (CH1 and CH2)may be in electrical communication to common drains separately. A commonsource of the n MOSFETs may be in electrical communication to PCB ground(GND). The common source of the p MOSFETs may be in electricalcommunication with the PCB's charge controller input voltage (CH+). WhenCH1 voltage is greater than CH2 voltage by the MOSFET gate thresholdvoltages, Q1 and Q4 may be “on,” connecting CH1 to CH+ and CH2 to GND.When CH2 voltage is greater than CH1 voltage by the FET gate thresholdvoltages, Q2 and Q3 may be “on,” connecting CH1 to GND and CH2 to CH+.For example, whether there is 9V or −9V across CH1 to CH2, CH+ will be9V above GND. Alternatively, a diode bridge could be used, however theMOSFET bridge may be more efficient compared to the diode bridge.

In some cases the charging cradle may be configured to be a smartcharger. The smart charger may put the battery of the device in serieswith a USB input to charge the device at a higher current compared to atypical charging current. In some cases, the device may charge at a rateup to about 2 amps (A), 4 A, 5 A, 6 A, 7 A, 10 A, or 15 A. In somecases, the smart charger may comprise a battery, power from the batterymay be used to charge the device battery. When the battery in the smartcharger has a charge below a predetermined threshold charge, the smartcharger may simultaneously charge the battery in the smart charger andthe battery in the device.

While preferred embodiments of the present invention have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the invention. It should be understoodthat various alternatives to the embodiments of the invention describedherein may be employed in practicing the invention. It is intended thatthe following claims define the scope of the invention and that methodsand structures within the scope of these claims and their equivalents becovered thereby.

What is claimed is:
 1. An apparatus comprising: a cartridge comprising:a cartridge body having a first side and a second side opposite thefirst side; a first pair of heater contacts comprising a first platecoupled to the first side and a second plate coupled to the second side;and heater comprising a wick and a resistive heating element in contactwith the wick, the heater further comprising the first plate and thesecond plate, wherein the wick and resistive heating element aresuspended between the first plate and the second plate; and a devicebody comprising: a cartridge receptacle for receiving the cartridge; anda second pair of heater contacts positioned to couple with the firstpair of heater contacts when the cartridge is inserted into the devicebody, coupling of the first pair of heater contacts and the second pairof heater contacts completing an electrical circuit for deliveringelectrical energy to the resistive heating element, the resistiveheating element configured to generate an aerosol.
 2. The apparatus ofclaim 1, wherein the first pair of heater contacts further comprises acontact surface disposed outside of the heater, the contact surfaceelectrically coupled to the first plate, and the contact surfaceconfigured to electrically couple with a heater contact of the secondpair of heater contacts.
 3. The apparatus of claim 1, wherein the firstplate is coupled to the first side using one or more of: pins; post; andcompression.
 4. The apparatus of claim 1, wherein the first pair ofheater contacts comprises a heat sink configured to absorb and/ordissipate heat produced by the resistive heating element.
 5. Theapparatus of claim 1, wherein the first pair of heater contactscomprises a heat shield configured to protect the cartridge from heatproduced by the resistive heating element.
 6. The apparatus of claim 1,further comprising: a power source electrically coupled to the secondpair of heater contacts; and a printed circuit board electricallycoupled to the power source and the second pair of heater contacts,wherein the printed circuit board comprises instructions which, whenexecuted, result in operations comprising: detecting an absence of fluidin the cartridge based on measuring a resistance of the resistiveheating element.
 7. The apparatus of claim 6, wherein the printedcircuit board comprises: switches; a reference resistor; and acontroller configured to cycle the switches at fixed intervals tomeasure the resistance of the resistive heating element relative to thereference resistor, the operations further comprising: controlling atemperature of the resistive heating element based on the measuredresistance.
 8. The apparatus of claim 7, wherein controlling thetemperature comprises: turning power to the resistive heating elementoff, when the measured resistance exceeds a control parameter thresholdindicating that the resistive heating element is dry.
 9. The apparatusof claim 1, further comprising: a plurality of contacts exposed throughan exterior surface of the device body, wherein the plurality ofcontacts are configured for electrical communication with a powersource.
 10. The apparatus of claim 1, further comprising: an air inletthat originates a first airflow path; and an aeration vent thatoriginates a second airflow path.
 11. The apparatus of claim 10, furthercomprising: a storage compartment configured to hold a vaporizablematerial; and an oven comprising the heater and an oven chamber, whereinthe oven is positioned along the first airflow path, and wherein anaerosol, generated by heating the vaporizable material, travels alongthe first airflow path.
 12. The apparatus of claim 11, furthercomprising: a condensation chamber configured to receive the aerosol,wherein the second airflow path joins with the first airflow path, priorto or within the condensation chamber and downstream from the ovenchamber, thereby forming a joined path, wherein the joined path isconfigured to deliver the aerosol to a user.
 13. A cartridge comprising:a cartridge body having a first side and a second side opposite thefirst side, the first side opposite the second side; a heater chambercomprising a wick and a heating element in contact with the wick, thewick comprising a fibrous material, the heating element configured toheat the wick to generate an aerosol for delivery to a user; and a firstpair of heater contacts, the first pair of heater contacts comprising afirst plate coupled to the first side of the cartridge body and a secondplate coupled to the second side of the cartridge body, the first plateand the second plate defining a volume therebetween, and a portion ofthe wick and a portion of the heating element disposed within thevolume.
 14. The cartridge of claim 13, wherein the first pair of heatercontacts further comprises a contact surface disposed outside of theheater chamber, the contact surface electrically coupled to the firstplate, and the contact surface configured to electrically couple with acontact of a device body and form part of a circuit with the devicebody.
 15. The cartridge of claim 13, wherein the first pair of heatercontacts comprises a heat sink configured to absorb and/or dissipateheat produced by the heating element.
 16. The cartridge of claim 13,wherein the first pair of heater contacts comprises a heat shieldconfigured to protect the cartridge from heat produced by the heatingelement.
 17. The cartridge of claim 13, further comprising: an air inletthat originates a first airflow path; and an aeration vent thatoriginates a second airflow path.
 18. The cartridge of claim 17, furthercomprising: a storage compartment configured to hold a vaporizablematerial; an oven comprising the heater chamber and an oven chamber,wherein the oven is positioned along the first airflow path, and whereinan aerosol, generated by heating the vaporizable material, travels alongthe first airflow path.
 19. The cartridge of claim 18, furthercomprising: a condensation chamber configured to receive the aerosol,wherein the second airflow path joins with the first airflow path, priorto or within the condensation chamber and downstream from the ovenchamber, thereby forming a joined path, wherein the joined path isconfigured to deliver the aerosol to a user.
 20. The cartridge of claim13, wherein the fibrous material comprises at least one of: a silicamaterial, a cotton material, and a hemp material.
 21. A cartridgecomprising: a cartridge body having a first side and a second sideopposite the first side, the first side opposite the second side; aheater chamber comprising a wick and a heating element in contact withthe wick, the heating element configured to heat the wick to generate anaerosol for delivery to a user; an air inlet that originates a firstairflow path; an aeration vent that originates a second airflow path;and a first pair of heater contacts, the first pair of heater contactscomprising a first plate coupled to the first side of the cartridge bodyand a second plate coupled to the second side of the cartridge body, thefirst plate and the second plate defining a volume therebetween, and aportion of the wick and a portion of the heating element disposed withinthe volume.
 22. The cartridge of claim 21, wherein the first pair ofheater contacts further comprises a contact surface disposed outside ofthe heater chamber, the contact surface electrically coupled to thefirst plate, and the contact surface configured to electrically couplewith a contact of a device body and form part of a circuit with thedevice body.
 23. The cartridge of claim 21, wherein the first pair ofheater contacts comprises a heat sink configured to absorb and/ordissipate heat produced by the heating element.
 24. The cartridge ofclaim 21, wherein the first pair of heater contacts comprises a heatshield configured to protect the cartridge from heat produced by theheating element.
 25. The cartridge of claim 21, further comprising: astorage compartment configured to hold a vaporizable material; an ovencomprising the heater chamber and an oven chamber, wherein the oven ispositioned along the first airflow path, and wherein an aerosol,generated by heating the vaporizable material, travels along the firstairflow path.
 26. The cartridge of claim 25, further comprising: acondensation chamber configured to receive the aerosol, wherein thesecond airflow path joins with the first airflow path, prior to orwithin the condensation chamber and downstream from the oven chamber,thereby forming a joined path, wherein the joined path is configured todeliver the aerosol to a user.
 27. The apparatus of claim 11, whereinthe cartridge further comprises the vaporizable material within thestorage compartment, and wherein the vaporizable material comprises anicotine formulation.
 28. The cartridge of claim 18, further comprisingthe vaporizable material within the storage compartment, wherein thevaporizable material comprises a nicotine formulation.